Problems with 2005 Ford F-150 FUEL SYSTEM, GASOLINE

Ford fuel pump driver corrodes badly causing no start and/or total failure of engine power. reduction of power or engine stalling can and will happen at highway speeds. when engine stalls driver can lose power steering power brakes and control vehicle. this is known by ford. ford along with a aftermaket company has redesigned the part. the updated part has standoffs along with a protective coating preventing corrosion. the corrosion of the part happens faster in the salt belt states. i replaced mine and the part had a hole in it letting water and parts of metal inside unit. i still have part if needed. do an internet search and you will find allot of examples of this issue. this issue affects millions of vehicles. *tr

Engine cut out while driving vehicle. would not restart. because i was stranded in the middle of a busy road, there was a 2 car rear collision that occurred behind me. repairs were $400.00 for me not to mention the cost and injury of the other cars involved in the accident behind me. i have since learned that this fuel pump module is a common problem in this truck due to corrosion problems resulting from a poor design. it is my opinion that this should be a recalled item. *tr

Truck started stalling in traffic & intersections. had to continue to restart. finally made it home. then took it in for repair. remove & replace fuel pump control module (part was severely corroded) technician was surprised that the truck even ran. ford pick a poor location for such an important part of the fuel delivery system. should have been a recall item. repair cost me $413.08. *tr

Truck would not start after it was parked. after several tries it started long enough to driver to a local mechanic. mechanic found a fuel injector was stuck open pouring gas into the cylinder and oil. vehicle towed to ford dealer for repair. dealer found a fuel injector was stuck open pouring gas into the cylinder and oil and a bent rod, their recommendation is a new engine. ford had issued a customer satisfaction program 07m08 to cover the fuel injectors to 11 years or 120,000 miles but since i was at almost 9 years and 134,000 miles ford no longer claims no responsibility for the cost of repair of a known and published problem or to its customer. some satisfaction program. *tr

I was pulling out into traffic when the engine wouldn't respond. luckily it wasn't on a highway the on coming traffic had enough time to avoid me. there was no warning i thought the truck had died and went to restart but the engine was idling. i then put the truck into low transfer and was able to move to a safe place by idling until a tow truck could remove it. *tr

Tl* the contact owns a 2005 ford f150. the contact stated that while driving 30 mph the vehicle began to spill fuel into the street. the vehicle was taken to the dealer for diagnosis and the contact was informed that the joint on the tank had become delaminated. the manufacturer was notified but offered no assistance. the vehicle was not repaired. the vin was unavailable. the failure and current mileage was 52,300. updated 01/09/13*lj updated 1/11/2013 *js

Tl* the contact owns a 2005 ford f-150. the contact stated that while driving approximately 55 mph he noticed that the engine misfired. the vehicle was taken to an independent mechanic and the mechanic stated that the reverse spark plugs welded themselves to the engine head. the mechanic performed a tune up and replaced the spark plugs. the manufacturer was notified. the failure mileage was approximately 94,000. the vin was unavailable. updated 06/05/12*lj the customer stated ford replacedthe faulty fuel injectors. updated 06/06/12 *js

My fuel pump module shorted out. it had become corroded. there was a melting of plastic parts in the module. i could smell the plastic burning before the unit failed. the truck was running fine and then suddenly died when the module failed. fortunately, i was driving through a small town when this happened. if it would have happened on the highway it could have been a very dangerous situation. i feel ford should be performing a recall on these modules. it's a very poor design. i also feel that the truck owners should be compensated for the repairs that have already been done. *tr

Warning light: engine fail safe on i was forced to coast to a stop and turn off the vehicle. i restarted the vehicle clearing the warning and continued on. i took the vehicle to a local ford dealer where it was determined i needed to replace the throttle body and throttle position sensor.

My 2005 f-150 truck stalled right in front of my house just outside of my driveway, my neighbor and i had to push it in as to not block my street. luckily it didn't die out on the highway which i was on five minutes before it died out. i was thinking the fuel pump went, but with only 68,000 miles that would not be very good. after some research on the net this little part named fuel pump drive module gets my attention. i took down the spare tire took out the two bolts that hold the fpdm in and wow this part was corroded with a hole in it and a crack!!! so after $144.00 for part # 4l3z-9d370-a from ford dealer and about 45 minutes of my time, i'm rolling again, lucky for me no tow fees just a few beers for my neighbor. what a joke that ford can allow this bad design to continue and not be rectified by recalling all the vehicles this was installed on. i guess that wont happen till a few people lose there lives because of it. *kb

The problem started in 2010, it now has happen three times this year my 2005 ford f-150 supercab has without any warning, either lost all power or the engine was reduced to idle rpm at highway speeds. a total of five times this has happen since i bought the truck. its happen in all typs of driving, highway speeds, city driving, acceleration and at a steady speed. i have had to maneuver across busy freeway lanes while coasting. in three of the incidents in which the engine stalled, i had to accomplish this without power steering or brakes. in another incident, the engine was idling so p/s and p/b were functioning, but there was no response to throttle inputs for acceleration. the check engine and "wrench" warning lights were illuminated on the dashboard. after turning off the ignition switch, the vehicle re-started and i was able to continue, the wrench light went off after restart, but the check engine light remained illuminated until i have it reset. i been very fortunate that i have not been in an accident. this problem is intermittent and comes with absolutely no warning, it is clearly a safety issue. i now will not let my family drive the truck. *tr

Proceeded to drive out of home driveway onto road, which is gravel and travels immediately downhill. i heard a pop and what sounded like exhaust/compression popping and experienced the engine skipping with slight loss of power. i turned around, as soon as it was safe to do so, and drove back to my own driveway. i contacted a local mechanic which i use regularly and explained my situation. the mechanic was only able to check it out thursday 8, september, 2011. he then diagnosed the problem as a blown sparkplug and suggested i contact ford for some relief as the problem is widespread. i did and was denied. the problem, as i understand it, could have resulted in having raw gasoline spraying out of the spark plug hole, onto a hot manifold and possibly causing a fire. *tr

Vehicle stalls out completely when coming to a stop and at highway speed. vehicle goes into fail safe mode. very hard to control vehicle. vehicle can be restarted once put in park and shut off.

While driving i lost acceleration crossing lanes and was almost hit by a truck. *tr

We have a 2005 f-150 ford pickup. latter part of april 2011 i was coming home from work the truck just shuts off. will not restart. have it towed to the garage they scanned it and said the fuel pump and the fuel module needed replaced. order the parts through ford motor company , can't get them anywhere else. didn't receive them called again and put a rush on them may 5th, 2011. never received parts until in june 2011. we called several times to find out why it was taking so long and was told they were on back order. when we finally received them they said there was 1600 shipped out and 4300 on back order. done some checking and found out that there were many, many more people with the same problem. after getting the parts and having them installed now the check engine light comes on the garage scans it and now in needs a fuel tank pressure sensor and guess what nobody has one. i need this vehicle for my job and besides that this is getting very costly. i feel ford motor company should be taking care of this problem and reimbursing those who have spent all this money on this problem. after all four months is way to long to wait on parts to solve a problem especially when you have to get the parts from them. *tr

I bought my ford f-150/v/8 in 2005. since 2005 i have had problems with the fuel injectors to date (03/20/2011). i have spent close to $4,000.00 for problems resulting from the fuel injectors. although ford sent out a letter dated december 2007, referencing and acknowledging problems with the injectors sticking open/close. it has been a nightmare at the service departments. again although, ford extended the warranty on fuel injectors totaling 11 years or 120,000 miles from the start date. the customer pays for all other problems that occur as a result of the damage that the injectors caused. i experienced too much gas in the engine causing a bent rod. injectors sticking open and closed causing shut down of the engine or fast acceleration. i'm seeking reimbursement from ford motor company for monies spent form problems that were cause by the fuel injectors. i have been to the service 7 to 8 times problems associated with the fuel injectors. this problem has become a financial burden. *tr

Fuel pump control module is subject to corrosion due to location. i was driving up hill on the freeway when my 2005 f150 stalled. i lost all power, power steering, brakes. i was nearly killed when the semi behind me could not stop in time due to the failure of fuel pump control module. thankfully i was strong enough to force the truck to the shoulder and stop despite having no power brakes or steering while towing a 6000 lb trailer. after paying for a tow for my truck and trailer i find hundreds of reports dealing with the faulty placement of the fuel pump control module online. at the repair shop i was amazed by the extent of the corrosion. there was barely anything left of the module. the part was replaced with the same faulty controller due to a backorder from ford because the problem is so wide spread. i almost died due to a known problem that should have never been allowed to occur. *tr

My 2005 ford f150 loses the ability to use the gas throttle. i can still steer and the engine, lights, air conditioning system, and brake system still work. the has happened about two dozen times starting in oct 2010 and still occurring as of december 2011. i have had to swerve across freeway lanes on several occasions. the wrench sign comes on in the dash. i am able to shut the vehicle off and it turns right back on. the wrench goes away but the check engine light stays on. it really scares me because i visit the mountains in the winter and i am afraid this will happen on the way to the mountain and kill me or my family. i have heard numerous complaints online about this issue and it needs to be fixed. *tr

Tl* the contact owns 2005 ford f150. the contact stated that the vehicle was emitting an overpowering odor of gasoline fuel. the odor was most prominent when the vehicle was at a complete stop. the vehicle was taken to the dealer yet the vehicle was not repaired. the contact also contacted the manufacturer and was advised to take the vehicle back to the dealer. no further assistance was offered. the vehicle was not repaired. the vehicle failure and current mileages was 87,240.

Check engine light came on with code p0442 indicating evap emission control system small leak. mechanic performed smoke test and found severed fuel line on top of the fuel tank. it appears the line was faulty in that it was relatively protected on top of the fuel tank. also, this line is directly adjacent to the muffler which is a potential fire hazard. *tr

2005 ford f-150 injector failure. ford motor company will reimburse for injector failures that are "opened or stuck". the dealer diagnosed that one of the four injectors in my truck is electrically failed. the vehicle has 53,500 miles. i can't justify paying $200 - $300 for failed injector. *tr

1. i was driving down the road (snow and ice covered) and while making a left hand turn through an intersection my truck instantly died. when the truck died a lost power searing, brakes, and obviously acceleration. the entire intersection was blocked for 30-45 min. due to an earlier snow storm, no tow trucks were available. 2. the failure happened once. when the failure happens, the driver looses engine, brake, and steering power. the cause of the problem is a faulty fuel pump control module. the part fails because it is mounted underneath the bed of the truck but was not made resistant to road salt corrosion. 3. ford knows about this issue (and has a replacement corrosion resistant part) but the kit for this is in such high demand that it is back ordered until the middle of may. the dealer is telling me my truck is "fixed" but no one is able to prove i have the corrosion resistant part. there is documented communication between ford and the dealer about knowingly installing the old, defective part. *tr

I have had 2 incidents in the last 6 months with my 2005 ford f150 xlt with the 5.4 v8 and auto trans where the truck has had the electronic throttle body fail. what happens is the engine goes to "idle" and the transmission simply coasts. an orange wrench light indicates on the dashboard. stopping the truck, shutting off engine, then restarting the truck restores operation. after the first incident, i phoned the dealer and they said most likely it was the throttle body causing the problem or as a second possible problem area, the potentiometer at the gas pedal. both incidents happened on state highways at light traffic times so i was able to pull off road safely and restart vehicle to restore normal operation. i am very concerned about the safety of this system. the dealer told me that the early model electronic systems had been problematic but no recall had been issued for them. if this system "fails" on a vehicle in heavy traffic on an interstate like our 285 in atlanta, ga the result could easily be a collision resulting in certain injury if not death. please let me know what actions have been taken to remedy this problem. thank you. *tr

Vehicle just died. the fuel pump control module was replaced. *tr

Vehicle stalled out in the middle on the freeway at rush hour. vehicle towed to shop and inspected for cause . was told the fuel pump driver module corroded up and cracked in two parts and stopped the fuel pump from pumping fuel to the fuel injectors. the shop had a hard time buying the part from a ford dealer ,the part was on back order and the one dealer said he had 3 vehicles waiting for parts. this truck was running fine and it just quit it was not a fun day when it quit. *tr

While at ~45mph, i eased off the accelerator to go into a left hand turn. my f150 then lost all power and shut off (no power steering, etc), and there were 2 tracker trailers coming in the opposite direction from me. i was barely able to complete the turn with the momentum that i had before the truck died. the truck re-started without any issue. this had happened before 2 other times with large gaps of time in between (once in november 09 and the other time a week before this latest incident). the other 2 occurrences were similar (highway speeds of 60mph), and restarting without any issue or error codes. an error code was generated (finally) with the incident described at the top of this complaint, and i brought the truck to the dealership. they diagnosed a faulty throttle sensor which was replaced. at less than 50,000 miles i did not expect to see an issue with this sensor, and certainly i would expect the truck to default into the "limp home mode" described in the manual, which it did not. there were several other similar complaints for this on some forums and i felt it might need some attention. *tr

Fuel injections. i took my truck in for a whistling problem. they put it on the computer and told me everything looked great. no problems . two days later the truck was in the dealership becacuse of a smoking problem and they replaced fuel injector #8. a covered service. ford was aware of the problem but did not send recall notices. one week later the check engine light came on, the truck went into the shop and they replace fuel injector # 1 and #5. now i find out that ford will not replace all the fuel injections at once. only when there is a problem. i asked them why the computer said everything was ok and then ended up with the fuel injector problems. they didnt have an answer. further more the other fuel injectors can go out at any given time. hope im not in the mountains when that happens.*cw

Driving home @ (highway speed 55+) from a family gathering. service engine light illuminated. engine lost power. i tried to accelerate. no throttle response. engine stalled. had to find place to pull over with no power steering. returned gear selector to p. turned ignition to off position. restarted and completed trip. 50+ miles. this event has occurred two times. i have been very lucky that i had a place to pull over and restart the vehicle. if i had been entering or driving in high speed traffic this failure could have caused a major accident. i read discussions on 2005 f150 web site that relate to this type failure. scanned for engine codes. tps fault code. replace throttle body. i will retain old parts. *tr

Since june of 2009, my 2005 ford f-150 supercrew has, without any warning, either lost all power or the engine was reduced to idle rpm at highway speeds three times. each time, i was in rush-hour traffic and had to maneuver across busy lanes while coasting. in the two incidents in which the engine stalled, i had to accomplish this without power steering or brakes. in the third incident, the engine was idling so p/s and p/b were functioning, but there was no response to throttle inputs for acceleration. the check engine and "wrench" warning lights were illuminated on the dashboard. after turning off the ignition switch for several seconds, the vehicle re-started and was able to accelerate normally, but the check engine light remained illuminated for several days (the "wrench" light went off after re-start). i was fortunate in that i am a very confident driver and was able to quickly assess the situation and react properly to get safely to the side of the road. if my wife had been driving the vehicle, i fear that she would not have been so lucky. in doing research on this problem on the internet, it appears to be wide spread over multiple vehicles (f-150, expedition, etc.) manufactured in the 04-05 time frame. as this problem is intermittent and comes with absolutely no warning, it is clearly a safety issue for drivers of these ford vehicles. i have checked my vin on the ford website, and there has been no recall issued. please help! *tr

Tl*the contact owns a 2005 ford f-150. the contact noticed white smoke coming from the exhaust. the vehicle was towed to the dealer and they stated that the fuel injectors failed, thus causing the engine to fail. the cost to replace the component would be approximately $7,300. the manufacturer stated that there was an initiative that would extend the warranty on the fuel injectors. the contact is waiting on a decision on whether the manufacturer will assume financial responsibility. the failure and current mileages were 73,000.

Tl*the contact owns a 2005 ford f-150. while driving approximately 35 mph on normal road conditions, the bed and cab compartments of the vehicle burst into flames. the contact was notified by another motorist. he immediately turned off the engine and exited the vehicle. he noticed fuel leaking from the vehicle onto the roadway, which also caught fire. the vehicle became engulfed in flames and was destroyed. there were no warnings prior to the fire. the fire and police departments were called to the scene and a report was filed. the fire department stated that the fire originated on the top surface of the fuel tank. there were no personal injuries or property damage. the vehicle was towed to a collision center. the manufacturer was notified of the malfunction and the insurance company has not determined the cause of the failure. the failure and current mileages were 47,000.

While driving into town i decelerated and the engine stalled. i put truck in neutral and refired the engine. after that the emissions light was on. took truck to mechanic and said the throttle body failed. mechanic replaced throttle body and it cost 450$ parts and labor. *tr

My 2005 f-150 lariat ford pickup truck suddenly began to surge as i was pulling into my driveway. white smoke was billowing out the tail pipe. i was able to complete parking of the vehicle. i turned off the engine and then tried restarting but it would not start. i called a nearby ford dealer and they dispatched a wrecker to bring the truck to the ford dealer garage located a few miles away. once the truck was looked at the dealer called to inform me that a fuel injector had gone bad and that ford was aware of the problem and had extended the warranty on this model year of pickup truck to 111,000 miles. the truck was out of the 35,000 miles warranty. ford said there would be no charge to repair the injector. i'm wondering why there was no recall by ford since they admit they are aware of the problem. should the injector have failed while driving at a higher speed there could have been an accident and possible loss of life. *tr

2005 ford f-150 5.4 liter engine; all service work was performed at the recommended service intervals on this vehicle. at 102,000 miles, i took the vehicle to the dealership to have spark plugs replaced. (ford recommended 100,000 mile tune-up) the first three spark plugs attempted to be removed by three different technicians broke off even when following the ford tsb proceedure. this tune up will cost me almost $2,000 due to the defective spark plug design. ford will not help with the repair. *tr

Vehicle fuel injectors filled engine with gasoline and caused motor and oxygen sensors to fail. ford motor company has identified the problem but is refusing to fix injectors until they fail. *tr

The truck started cutting out and acting like it was not getting any fuel. we continued to drive the truck home and turned the truck off. the next day went out to start truck did not want to start had it towed to ford dealer. they said due to fuel injection malfunction the motor had to be replaced. *tr

My truck has 56k on it bought it used with 35k on it when it starts runs with high idle and the top end ticks really bad the ticking does not go away at all speeds at a stop light it sounds like a diesel tic tic tic sounds like a lifter is stuck. i put "lucas" in it to try to make it go away then i changed the oil ran about two weeks with no difference and changed it again and no change called ford dealer they couldn't help they said i would have take it in and get charged $165. then i changed the spark plugs maybe a fouled plug that wasn't it there goes 120 bucks a couple of weeks ago my wife was driving on the freeway and the drivers side window falls the window regulator broke $140 replaced that already. the passenger seat belt locks up sometimes now to the front the steering wheel shakes really bad when you apply the brakes turned the rotors at napa $20 new brake pads $90 at kragens balanced tires free i work at a tire shop shaking went away ...

Gasoline fuel injectors staying open and dumping raw uncontrolled fuel into engine causing cylinder failure. now ford dealership states i must pay for 1/2 of cost of a new engine. required 2 service visits to get truck running again and still after $800+ more dollars in repairs is not running properly. *tr

The 2005 ford f150 crew cab has been having problems with its throttle body actuator. this problem will cause the vehicle to either stall or lose power with out any notice. *tr

Tl*the contact owns a 2005 ford f150. while driving at speeds over 20 mph, the vehicle would shake and vibrate violently. he also observed black smoke emitting from the exhaust pipe and a strong gasoline fuel odor from the vehicle interior. the vehicle was taken to the dealer where they replaced the fuel injectors (performed under ford customer satisfaction program 07m08, nhtsa service bulletin number : 07m08, fuel system, gasoline:fuel injection system:injectors) and made repairs to the brake booster (performed under nhtsa campaign id number: 08v208000: component: service brakes, hydraulic:power assist:vacuum:hoses, lines/piping, and fittings). immediately after the repairs, when putting the vehicle into the drive position, there was a rattling noise under the vehicle. the vehicle was taken back to the dealer who stated that the catalytic converter was damaged due to the fuel injector failure. the dealer was advised by the manufacturer that the catalytic converter would not be covered and they would take no liability for the failure. there were no repairs made to the catalytic converter, to date. the contact has all service records, if needed. the failure mileage was 35,742 and the current approximate mileage was 84,000.

Truck continues accelerating after foot is removed from accelerator pedal. almost impossible to stop with brake pedal. had to take out of gear to stop truck. restarted truck and it operates properly. it has happened three more times since this original occurrence. ford dealer could find no problem in 2007. am taking it back again as it has happened twice in the past year. *tr

While operating vehicle in cold conditions or on cold starts the engine races. also during this time as you try and apply the brakes the motor races and if in gear it will surge/leap forward. this cause the vehicle to crash into a block wall and damage the front end of the truck. *nm

Dt*: the contact stated while driving 40 mph, the vehicle hesitated and stalled. it was maneuvered off the road and later driven to the dealer who determined the fuel injectors failed causing engine damage resulting in the engine needing to be replaced.

2005 f150 rwd vehicle has been into ford repair 3 times for brakes (parking brake, abs). one occasion the temperature of the lt rear hub was 385 degrees f by inferred thermometer. another occasion rt rear was too hot to touch after sitting for an hour. this vehicle has aluminum rims that the dealer states show no damage. also unknown is what this temperature may have caused to the rear bearings, seals and other brake components (calipers). abs light intermittent on and driveablity was intolerable with shaking and vibration. fuel consumption got worse by 30%. vehicle taken to dealer and parts were replaced (rotor, abs sensor, parking brake reattached) , parking brakes was found disconnected in the semi locked position on the second return, missed on first return. unable to get old parts. *nm

My wife was at a complete stop at a red light in the left turn lane. she is driving a ford f150 truck, with less than 6,000 miles. while waiting at the light, the engine began accelerating unexpectedly. she had her foot on the brake and this initially held the vehicle in place. the acceleration continued to increase and she pressed harder on the brake petal, in an effort to keep the vehicle from moving forward. the vehicle's acceleration increased and the vehicle lurched forward, striking the stopped vehicle in front of her. no one was hurt and i had the vehicle towed to the ford dealership. the service tech at the dealership, told me that it could be a number of problems with the fuel injection system. it should be noted that the day before, i was driving the truck and while stopped at a red light, i thought i heard the engine running in a loud or rough manner. i turned the radio off and listened intently. i check the gauges and they were find. the light changed and i drove forward and the funny noise went away. could this have been an indication of bad things to come? finally, i found a similar incident on the nhtsa complaint site, dated september 8, 2005. the incident on that date is almost exactly what happened to my wife. *nm

Dt*: the contact stated while the heater is engaged gas fumes are detected in the vehicle. in an attempt to remedy the problem the dealer replaced the fuel injectors, spark plugs, starter, fly wheel, transfer case, and catalytic converter with no success.

Shuddering, shaking, rough idle, banging when re-applying gas after coasting and stalling at intersections. then manufacturer has replaced 5 fuel injectors so far and the truck is running rough again. i have 23k miles. *jb

Dt*: the contact stated while sitting inside the vehicle there was an odor of gasoline. the vehicle was inspected by the local dealership, and they replaced 7 fuel injectors, 8 spark plugs, and ordered a fuel rail. these attempts to solve the problem have been unsuccessful. *ak updated 01/25/06. *jb

Runaway throttle/un-commanded acceleration event. brand new vehicle, only 110 miles on odometer. while waiting for a stoplight with right foot on brake and transmission in drive, engine began accelerating unexpectedly. neither i nor anything else in the vehicle was pressing on the accelerator in any way. the un-commanded acceleration increased. i pressed harder on the brakes and the acceleration continued to increase, to the point that the rear wheels broke loose and started to squeal (this is a rwd vehicle). then i moved the transmission selector to neutral, at which time the torque to the rear wheels was removed. the engine raced to about 3000-3500 rpm as observed on the tach and then returned to normal idle. at this point everything was normal, so i continued to drive to work since i was very close. no further problems were noted. i parked the vehicle in our parking lot and called the dealer (berge ford, mesa, az) for further advice. all of this happened within about a three second period. the vehicle had been started from cold at about 6:30 am after being parked in garage overnight (on board thermometer read 89 f when i started out). runaway throttle event occurred after driving about five miles. air conditioning was on the entire time. *jb

I purchased a 2005 ford f150 (lobo edition) in san antonio texas in june 2005. we picked it up a week later so they could install a bedliner.on the way home i came to a stoplight,pressed the brake, and the truck started reving(like i was pressing the gas too!) so i was at the red light and had my foot on the brake and the truck was acting like it wanted to take off! my husband drove it and it happened to him 3 times(the first time i was with him). while my husband was coming to a stop, the truck accelerated (while he had his foot on the brake!) he almost drove completely into a ditch. the last time it happened he was in reverse with his foot on the brake. we called ford and they picked it up and took it to the nearest service center. the truck only has 80 miles on it. the ford service manager in uvalde texas called me yesterday and said they cannot reproduce the problem so they don't know how to fix it.