Problems with 2005 Ford F-150 ENGINE AND ENGINE COOLING

Tl* the contact owns a 2005 ford f-150. while driving approximately 30 mph, the exhaust pipe detached from the vehicle. the vehicle was taken to an independent mechanic and it was discovered that the entire subframe of the vehicle was rusted and corroded, including the damaged exhaust pipe. the exhaust pipe was repaired, but the subframe was not. the manufacturer was notified of the failure, but the local dealer was not. the vin was not available. the failure mileage was 70,000.

Cpsc;2005 ford f-150 transmission and motor went out at 89446 miles. a diagnostic was performed. *bf the consumer stated after the transmission was replaced, the vehicles performance was not indicative of having been at a repair shop. the consumer returned to the dealer and another diagnostic was performed. the consumer was then informed the engine needed to be replaced. it was also determined the initial repairs were completed with salvaged/used parts. *jb

2005 ford f-150. consumer writes in regards to spark plugs and coils problem. *smd the consumer stated the vehicle stalled, upon acceleration. the consumer also stated the check engine light illuminated and flashed when a spark plus misfired. *jb

Ford designed the factory spark plugs as a two piece design. once the truck requires a tune up the current spark plugs break in half as they are removed causing an addition cost for extra labor and special tools designed to remove these plugs. i took my truck to the ford dealer who then broke 6 out of 8 plugs upon removal at an extra cost of 80 dollars a piece. the tune up which only includes the removal off the old and the installation of the newly designed one piece spark plugs ended up costing me 1000 dollars. these spark plugs also break inside the engine causing a loss of power and possible damage to the catalytic converter. *tr

When taking my vehicle out for test drive after putting new brakes on. while driving an spark plug blew out. while checking online i found that this is a major problem. i was very upset to find out from the dealer that it's gonna cost $585.70 to fix one spark plug and replace coil. i asked about replacing all the plug and they quoted $900 to do all of them. as a retiree of ford i think this is crazy. they tell you in the manual that the plugs are good for 100,000 miles. the mechanic said there is no guarantee that this won't happen again even if we replaced all the plugs. i'm thinking of trading my truck off and am considering another brand. *tr

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

While driving home truck shut off engine fail safe mode indicator came on engine shut off all functions,brakes power steering. *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

Cross-reference ford tsb 07-13-5: water leak from ac has flooded the passenger floor pan and all associated carpeting and padding. significant health hazard exists in warm climates due to the proliferation of respiratory hazards including but not limited to legionnaire's disease. the item should be a recall for this reason. i have lost use of my truck due to the inability to sufficiently dry the padding - i have had the vehicle drying for one week in hot florida sun to no avail. *tr

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

#3 spark plug blew out while traveling away from home in another state. in driving two miles back to my son's house, i had two explosions from excess gasoline and spark plug firing. the spark plugs were original and blew out because of the fine threads and aluminum cylinder heads. this is a design defect and safety problem known to ford. towing and insert installation by a ford dealer was $950. the engine is a 4.6 v-8 updated 05/17/12 *bf

Ford factory spark plug breaks within the head causing potential internal engine damage. an extremely common issue that has lead to the invention of a special tool used just because f the issue. commonly reaching hundreds and even thousands of dollars to repair. ford has changed their tsb from changing plugs at 100k miles to 60k miles. however by the time a issue was noticed many of us owners have over the 60k mile mark. *tr

Tl* the contact owns a 2005 ford f-150. the contact stated that while the vehicle was parked, a loud pop noise was heard and the vehicle erupted into flames. the vehicle caused extensive damage to a commercial building in which it was parked near. the police were contacted and a police report was filed. the fire department did not determine the cause of the fire. the manufacturer was not contacted. the failure mileage was approximately 78,000. updated 03/28/12 *bf updated 03/30/12

Yes my 4x4 is not working and i have read over 300 post easy about the same problem people are having. thousands of people are having the same problem i have had with my truck. obviously if there are that many people with the same year of truck and same problem why isn't ford doing a recall? they say the problem is the iwe, solenoid, the problem why it happens in the first place is there isn't a rain cover over the solenoid underneath the hood. i do believe that this is a huge safety hazard and almost caused me to be in an accident about three weeks ago because my four wheel drive went out! ford please do a recall before someone gets hurt or even die! i do believe that ford should be responsible for this issue and have a recall to get these vehicles fixed. *tr

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

Auto ran great,fuel mileage real good,then sparkplug blew out without any advance indication of a problem. *tr

Vehicle misfired on acceleration on highway. was aware of spark plug ejections w/ my particular year and model after going through camshaft phaser repairs. (2005 f-150 w/ 5.4l triton engine). mechanic suggested replacing all factory spark plugs w/ new designed spark plug kit to eliminate ejection problem. i did so at a cost of $831.52. costs to date $4729.25 within the last 2 months on a 2005 vehicle. unacceptable. researched on internet and found this to be a very well known problem. no mention of it from the dealer upon purchase. ford has turned their back on this (and the camshaft phaser defect). i am a small contractor whose livelihood depends on this vehicle. the purchase price of $35,890.00 plus tax and license was a huge investment for me (i paid cash and drained my savings so i would not have monthly payment). so these additional costs to an almost new vehicle have drained my account again. *tr

Tl* the contact owns a 2005 ford f-150. the contact stated that the vehicle was idle and in park when it exhibited an abnormally loud popping sound. the vehicle was taken to the local dealer who diagnosed that four cylinders were defective and needed replacement. the vehicle was not repaired. the dealer and the manufacturer were notified of the failure but denied any assistance with repairs. the failure and current mileage was 61,000.

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

Camshaft phasers failed so engine would not idle, causing a very dangerous situation at stop signs having to constantly rev engine to keep running. repair cost $3,897.73. through internet investigation have found my particular year and engine (5.4l triton) has a history of this failure. told that a non-motorcraft oil filter can release debris that clogs a lubrivation port in the cam phasers which in turn destroys them. no info. of this sort was ever relayed to me on purchase of vehicle. i have no reason to believe i have ever used anything but a motorcraft oil filter. a 2005 vehicle w/ a $3900.00 mechanical repair is unacceptable. have contacted ford until i have exhausted my attempts. they finally told me this was the end of our communications. *tr

Tl* the contact owns a 2005 ford f-150. the contact stated that while driving, he heard an abnormally loud noise from the vehicle. he inspected the vehicle and noticed that a spark plug from the cylinder block had ejected. the vehicle was taken to the dealer who verified the failure and stated that the block needed to be re-threaded. the manufacturer was made aware of the failure who did offer any assistance. the vehicle was not repaired. the failure and current mileage was 120,000.

Tl* the contact owns a 2005 ford f-150. the contact stated that faulty spark plugs fractured in the cylinder head and the remains became stuck in the engine block. the vehicle was taken to an authorized dealer, but was not repaired. the manufacturer was made aware of the failure, but offered no assistance. the failure mileage was 95,000. updated 08/01/11*lj the dealer had the vehicle for four weeks to remove the spark plugs. the consumer paid $ 467.50 in labor. updated 08/11/11

2005 ford f150. consumer states engine shuts off and vehicle continues to go into "fail safe mode" *tgw the consumer stated there were times when the vehicle would re-start, and other times it wouldn't. the consumer stated several components such as the fuel filter, catalytic converter, fuel pump module, throttle body, and crankshaft position sensor were replaced to try and rectify the problem. the engine began to misfire and the check engine light illuminated. the consumer stated it was finally determined, the casing on the crankshaft position sensor wire had rubbed through and was shorting out on the ac line running along the right fender well. the consumer stated at some point when his vehicle was being serviced at the dealer, a cover was removed from the far left wiring harness at the pcm, which permitted water to run down the inside of the wiring harness and shorted out the connector. jb

Tl*the contact owns a 2005 ford f150. the contact stated that the motor was faulty due to the design, causing a carbon build up that blocks the spark plugs. the vehicle was towed to the dealer; however, the dealer was unable to remove the spark plugs. the manufacturer referred the contact to nhtsa to file a complaint. no repairs were performed. the current and failure mileage was 131,000.

2005 ford f-150 spark plugs fuse to engine and break very easily. the truck has less than 100,000 miles and was brought to the dealership for a tune up. the dealership tried to remove the plugs and they broke. they are now forced to remove the header and replace the plugs. this is now going to cost $2600 for a known problem with the manufacture provided plugs. *tr

Tl* the contact owns a 2005 ford f150. the contact was driving at relatively low speeds when the brakes were applied and the vehicle stalled. the vehicle was taken to the dealer where the contact was advised that the engine mass air flow sensor failed. the vehicle was not repaired. the failure and the current mileage was 90,000.

2005 ford f150 spark plug ejected from engine. *tr

2005 f150 supercrew 4x4 lariat; with a 5.4 3 valve/cylinder engine; check engine light came on and indicated cylinder 5; mechanic went to pull the plug which broke in two with the bottom part still in the block. had to have it towed to a ford dealer; $150 to remove the plug plus $29 parts and labor. plug has a design flaw that ford has known about since at least 1997. for most triton egnine owners, you find out the hard way when the engine light comes on or when you go in for a tune up; minimum cost $150; for every broken plug - $150 to remove it; if it can not be removed, the engine and/or front end has to be pulled (per ford repair bulletin) to remove the head(s). cost: $1,000 - $3,000. most vehicles are "out of warranty" by this time which ford then dismisses as not a "warranty problem" but rather a "service issue". the dealerships make a killing off the customers because of an inept, incompetently designed spark plug. ford has known about this problem since the late 1990s but refuses to do anyting as the ntsb has done nothing to issue a recall. duh *tr

Tl* the contact owns a 2005 ford f150. while driving approximately 20 mph, the check engine light illuminated and the vehicle was taken to an independent mechanic for inspection. the mechanic informed the contact that a spark plug had fractured in the head of cylinder five. the manufacturer was contacted and stated there were no recalls for the failure and suggested the contact keep all receipts for possible reimbursement if there was a recall in the future. the vehicle was not repaired and the vin was not available. the approximate failure mileage was 100,800.

My 2005 ford f150 quit while driving down the highway with my 12 yr old son. engine began to spit and sputter and stranded us on the highway. after towing to my local ford dealer. the dealer discovered the timing chain had slipped causing the truck to jump time and ruining the engine. the truck has 130,000 highway miles. now they want $7,500 for a new engine. the other issue is my rear driver side window just fell into the door. they want between 200 and 300 dollars to repair.

While driving vehicle at any speed from 10 mph to 70 mph the truck will go into safe mode (limp-home mode) going down to 5 mph and losing all power steering. when diagnosed it is the throttle body control to me this is a safety issue what happens if i am driving 70 mph on the highway and it goes into safety mode and i lose all power steering. does someone have to die before there is a recall on this??? it will cost me around $1000.00 to fix per brondes ford in toledo ohio and i am told ford has 2 or 3 vehicles a week come in for the same problem. to me this is not standard maintenance.

Attempted to have spark plugs changed in accordance with vehicle maintenance manual at 100,000 mile. while this was being done 3 factory installed motorcraft spark plugs broke off. as a result i was charged a total of almost $700 for the removal of these broken plugs. the dealership technician informed me that 100% of all 2004-2007 f150 trucks that have the plugs removed as required at 100,000 miles have plugs that break. ford nor the dealership would cover the cost of this defective product and defective ford design. *tr

Spark plugs breaking off in engine head because of poor design. just happened to me and after looking around the internet it has happened to a lot of people and now the service department of my local ford dealership says it common and now they are charging me becuase they broke it and its common. *tr

Tl*the contact owns a 2005 ford f-150. the contact stated that the spark plugs in the engine popped out of the cylinder head which indicated that there was not enough thread on the spark plugs. the vehicle was taken to a local repair shop where the spark plugs were replaced. neither the dealer nor the manufacturer had been notified. the failure mileage was approximately 100,000.

While driving, my 2005 f-150 would suddenly act as if the transmission was in neutral. the wrench symbol on the gauge panel would illuminate, but the engine was still running. the only way to clear the problem was to pull over, put car in park, shut engine off, restart engine and shift to drive. luckily this never happened on the highway, but it could have led to a serious accident. i had the truck repaired, and the dealership had to replace the throttle body. this is not covered under warranty according to the dealership. truck has only 58,800 miles on it. i have seen this issue on this site and others and nhtsa really should investigate this issue. *tr

Tl* the contact owns a 2005 ford f150. the contact stated that the vehicle exhibited an abnormal grinding noise from the engine whether the vehicle was parked or in motion. the vehicle was taken to the dealer but the mechanic was unable to diagnose the failure. the vehicle was not repaired. the approximate failure mileage was 105,000.

I own a 2005 ford f-150 which i received a letter from ford stating that my fuel injectors were given a defect only extended warranty to 150,000 miles. i have had a few injectors replaced since the letter because of defect..i.e white smoke from exhaust and stutter of engine while driving. right after my last replacement of a fuel injector my catalytic converter was giving a bad odor..afterwards i had a diagnostic checked and the outcome was a bad converter. after several forums i have read i have noticed that several....several.. people have catalytic converter problems after the replacement of fuel injectors..some even having two or three replaced within just a few thousand miles and after having another fuel injector replaced. is the fuel injector problem a problem for the converter..its a big coincidence that so many have had the same problems after replacing defective fuel injectors.. *tr

Tl*the contact owns a 2005 ford f150 truck. while driving 35-40 mph the vehicle the vehicle was skipping and jumping and it was later towed to a local mechanic who had to remove the engine head in order to reach the spark plugs. the mechanic could not get all of the spark plugs out of the vehicle and referred him back to the dealer. the local mechanic repaired the vehicle for $900 since the dealer wanted to charge $2800 to repair the vehicle. the contact stated that because of the design of the vehicle the spark plugs were difficult to reach. the failure mileage was 75,000 and the current mileage was 80,000.

7 of 8 spark plugs broke off while changing out on my vehical this is crazy heard alot of complaints. *tr

Tl*the contact owns a 2005 ford f-150. the contact stated that the vehicle stalled without warning. the failure was intermittent. the contact called the manufacturer who stated that someone would inspect the vehicle. there were no warning lights prior to the failure. the failure mileage was approximately 71,000 and the failure mileage was unknown.

Notified today that there is an issue with removing and replacing spark plugs for the ford 5.3 triton v8 3 valve engine. ford has issued a technical service bulletin tsb 08-7-6 and it is not available on your website. why? if this is indeed a manufacturers defect should it not be covered by their original warranty or the magnusen-moss warranty act and or the ucc, article 2. this procedure can be both timely and costly for a consumer. i have received quotes ranging from 250 to 1600 dollars. should the consumer be expected to shoulder the burden of this issue? *tr

In the 2005 ford f-150 with the 5.4 liter 3 valve there is a defect pertaining to the spark plugs. in the event that you try to remove the spark plugs they tend to break off in the head possibly damaging the threads of the spark plug hole. when this occurs, ford is charging an outstanding amount of money to repair it. this problem is all over the internet and doesn't just affect the 2005 model. it is a very serious defect costing people a lot of money that i think should be placed on the manufactures plate. it is almost as if they designed this problem on purpose to make people have to bring it to their repair shop and have it fixed regardless of the price. i have personally experienced this problem along with many others and i think it is obvious that the customers are not happy with the way ford has handled the issue. spark plugs are considered to be part of preventive maintenance but this is sickening how they can get away with charging that much for a small problem. the problem was not discovered until ford had sold so many of them that it would probably take them years to correct every one. it is pretty much guaranteed that you are going to break off at least one of your plugs while trying to do this small task. as far as i know the only thing done to correct the problem was they invented a tool that will removed the broken part of the spark plug in the head, but if the threads get messed up in the process that's when it begins to start costing big bucks and it is totally the manufactures fault to begin with. please take this request for a recall seriously as i am not the only one who feels this way, just look online. *tr

2005 f150 just dies without any warning. driving down the hwy and just dies. it happens frequently, just dies, it always takes a few tries to get it restarted. we were told that the throttle body needs to be replaced. we know at least 4 other familys that also have 2005 f150's and they have experienced the same problem. my co-worker has hers in the ford shop right now and they are charging 1300.00 to fix it. it seems to me that with all of the complaints this should be a safety recall and replaced by ford co. *tr

Approximately 2 years ago i purchased a 2005 ford f-150 extended cab truck. i have had no problems with the truck up until this point and my truck currently has approximately 67,000 miles on it. however, approximately three (3) weeks ago i noticed my truck "sputtering" and "missing" and having some difficulty starting. i took it to the dealership (kamaaina motor's) that i purchased it from. the mechanics are now telling me that the spark plugs broke off and fell into the engine "head". they have attempted to retrieve the pieces of the spark plugs (two as they are currently reporting) but they feel that the impact of the spark plugs falling into the head may have now caused my motor to freeze up. at this point they are recommending complete engine replacement for my truck which will cost thousands of dollars. i am devastated. this is my only vehicle and i still owe money to the bank to pay it off. i don't have thousands of dollars to replace the motor and i know can't just get another loan for another car. i have been reading online about this repeated failure on ford's fault of defective spark plugs and that this is common and of no fault of the owners of the vehicles. at this point my truck is still sitting at the mechanics and is not moving and i am without a car. is there not anything that the ford company can do to be responsible for their defective productions?? i devastated by this and have no idea what i am going to do to get back into a running vehicle so i can get to work and take my kids to and from school. please help????? *tr

Tl* the contact owns a 2005 ford f-150. while driving at 55 mph, the spark plugs disbursed from the engine and the vehicle lost power and stalled. the dealer was contacted and the contact was informed that the repairs would be at her expense. the vehicle had not been repaired. the failure and current mileages were 80,000.

Ford motor company-there was a service bulletin put out show there was a problem with the cam phasers and cam chain tensioner causing the engine to make noises and then engine failure there has been lots of complaintsto ford with nothing being done if you where driving onthe road and the engine blew couldcause a accident i contact ford and they have all most admitted to it that they new there was a problem i have found that there has been 1092 complaints over this problem and nothing done. i contacted ford and that's how i found out about you they keep saying there sending the complaint to another dept..but this is aproblem that could have been correct before the engine was ruined. *tr

While driving to work #5 sparkplug blew out of the block. with the engine still running fumes or gas vapors from the sparkplug hole and the spark from the coil pack can cause the engine to catch fire or even explode!!!! causing bodily injury or death to the occupant of the vehicle. *tr

Tl* the contact owns a 2005 ford f150. the contact stated that while driving 60 mph, a loud noise was emitted from the engine compartment. the contact mentioned that the failure recurred twice. the vehicle was taken to the dealer who diagnosed that the spark plugs were not torqued correctly, causing the spark plugs to be spewed from the engine block. the manufacturer was made aware of the failure who did not offer any assistance since the vehicle was not included in any recalls. the vehicle was repaired. the failure mileage was 87,000 and the current mileage was 120,000.

2005 ford f150 v8 4.6l driving down the road, spark plug popped out of the head. 65,000 miles, original plugs. *tr

At just over 59k miles on my 2005 f-150 5.4l triton v8 driving at 30 mph i noticed a ticking sound that increased/decreased with rpms. traveling about 2 miles further the noise increased in volume so i pulled over and raised the hood. the noise was coming form the passenger side of the motor and the motor was shaking as if miss firing or running iraticly. i had no engine warning light or any other notifications on the dash prior. i went directly to my mechanic. when my mechanic came out to see what was happening he knew right away what was going on. he has repaired this problem several times before. he said that i had blownout a least one spark plug. this is a known flaw with the triton v8 motors or rather the spark plug design that was put in the engine from the factory. the spark plug is a three piece design the is crimped together and ultimately cracks and separates over a period of time leading to literally blowing up. in some cases the threads in the motor where the spark plug screws in can be torn out. this requires re-tapping new threads or a heliocoil pack. this issue was not pointed out to me by ford prior so i could prevent possible damage and very expensive repair costs as i know they are aware of this problem and that is very wrong. the manual provided by ford with the truck says the spark plugs don't need to be changed until 100k. after further investigation online i found hundreds of others experiencing the same problem prior to 100k. i will be sending the bill to repair my truck to ford through my attorney as this is negligent behavior and a faulty design flaw that i could not have prevented. ford is sending owners of this motor down a path of guaranteed financial and potential physical harm. ford needs to stand up and own this mistake. *tr