Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.


hardly worth mentioning
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
56,106 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2005 Ford F-150 engine problems

engine problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2005 Ford F-150:

Unsubscribe any time. We don't sell/share your email.

2005 Ford F-150 Owner Comments (Page 1 of 2)

problem #26

Mar 192012

F-150 4WD 8-cyl

  • 79,968 miles


#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

- White Pigeon, MI, USA

problem #25

Jul 102011


  • 120,000 miles
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.

- San Antonio, TX, USA

problem #24

Jun 062011

F-150 8-cyl

  • 95,000 miles
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 the dealer had the vehicle for four weeks to remove the spark plugs. The consumer paid $ $467.50 in labor. Updated 08/11/11

- Newark, OH, USA

problem #23

Apr 162011

F-150 4WD 8-cyl

  • 97,000 miles


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.

- East Windsor, NJ, USA

problem #22

Oct 222010


  • 100,000 miles
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.

- Gaffney, SC, USA

problem #21

Jun 122008

F-150 Diesel

  • 95,000 miles
My 2005 Ford F-150 lariat 5.4L sounds like a diesel, I was told this is a very common problem with F-150's within 2003-2006. This is a result of either cam phasers or bad lifters.

- Rushford, MN, USA

problem #20

Jun 282010

F-150 4WD 8-cyl

  • 87,033 miles


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.

- Brooklet, GA, USA

problem #19

Feb 232010

F-150 8-cyl

  • 64,000 miles
2005 Ford F150 V8 4.6L driving down the road, spark plug popped out of the head. 65,000 miles, original plugs.

- Moore, OK, USA

problem #18

Feb 122010

F-150 8-cyl

  • 59,000 miles
2005 Ford F150, 5.4 V-8 engine, 59,000 miles incident 1) 02/7/10 - upon accelerating away from a stop light while turning left, the truck accelerator pedal became inactive. Truck was moving at 25-30 mph. Additional pressure applied to the pedal caused no acceleration. Light traffic allowed me to coast to shoulder where I was able to put the truck in park. Truck faulted into 'limp mode' that limits the accelerator pedal operation (per manual), this was indicated by the 'wrench' light on the dash, no check engine light appeared. Turned the ignition off, waited a ~15 seconds and restarted. Upon restart 'wrench' light cleared and accelerator functioned as prior, again no check engine light appeared. Incident 2) 02/12/10 - while driving on a federal highway at 55 mph in right lane the same sequence as incident one above occurred " the truck accelerator pedal became inactive. Being in the right-most lane I was able to coast on to the shoulder and avoid a rear-end collision. Same ?wrench" light was indicated on dash, same sequence was used to restart and drive off. This obviously could have been much worse had the situation been different, I.e. in high-speed lane or heavier traffic patterns. This is certainly a safety concern for driving public, both those in the F150 and on the road around them. Almost identical instances can be seen on NHTSA site for exact make/model/year truck. Administration should investigate and consider a safety recall to avoid future damage.

- Hamilton, OH, USA

problem #17

Sep 282009


  • 50,000 miles
The contact owns a 2005 Ford F150. During a routine inspection a technician concluded that five of the eight spark plugs separated from the engine head; however, no repairs were made. The manufacturer was notified and no assistance was provided. The failure and current mileages were 50,000.

- Hemlock, MI, USA

problem #16

May 262009


  • 115,150 miles


I have a 2005 Ford F-150 pick up with a 5.4 liter Triton engine. While driving on the highway the number 1 sparkplug was spit out damaging the head. The vehicle immediately slowed down in the middle of traffic. Ford said this is uncommon, yet there are thousands of complaints already filed about this particular engine through the NHTSA. I have to completely replace the engine.

- Orlando, FL, USA

problem #15

May 182009


  • 55,000 miles
Spark plugs cannot be changed because of design of cylinder head. This is a spark plug breakage inside the head. This is a common occurrence on 5.4 liter Ford motors as reported on forums and through word of mouth. 1998 to 2008 motors are notorious leading consumers to either pay huge repair bills or trade before they wish to trade. Also, someone wishing to change his plugs for proper emissions or proper maintenance is just screwed. Scared to death to have them changed even at a dealership. Ford mechanics even have trouble.this is no few vehicles. This is widespread.

- Lone Wolf, OK, USA

problem #14

Jul 222008


  • 90,000 miles
The contact owns a 2005 Ford F-150. While driving various speeds, the vehicle began to jerk, backfire, and run badly. In addition, the check engine light illuminated on the instrument panel. The vehicle had to be towed twice. The fuel injectors were cleaned twice and the dealer stated that the catalytic converter needed to be replaced. The VIN was unknown. The current mileage was 100,000 and failure mileage was 90,000.

- Greendale, NJ, USA

problem #13

Aug 222008


  • 102,000 miles
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.

- Chesterfield, MO, USA

problem #12

Jul 212008


  • 43,143 miles
Advised that the 2005 F-150 5.4 Triton engine has a history of spark plugs seizing in the engine and recommended that the plugs be replaced. Ford says the plugs will last for 100,000 miles. Tsb 08-7-6 issued by Ford to address problem. Had plugs replaced at 43,123 miles and had three frozen or seized costing over $300 in labor. Ford knows of problem and has not issued a recall to correct design flaw. Read many other similar stories on internet where citizens are paying thousands of dollars to get the plugs out and vehicle back in operation.

- Westerville, OH, USA

problem #11

May 092008


  • 98,919 miles
Since Jan. 08 there have been 3 dealers look at & supposedly fixed 5.4 liter Ford engine. Ford does not want to help with any expense & I have 3 other vehicles that have had same recurring problem. All the above started with recall and has gone downhill.

- Junction City, OH, USA

problem #10

Feb 012007

F-150 8-cyl

  • Automatic transmission
  • 45,000 miles
Known issue of spark plugs breaking off in the cylinders. Ford is well aware of this issue, but refuses to issue a recall for it. Due to the breakage, it has been known to cost well over $2,000 in repair costs; just for a spark plug change!

- Moreno Valley, CA, USA

problem #9

Dec 152006

F-150 8-cyl

  • Automatic transmission
  • 20,500 miles
I had stopped at a local shop on my way back to work and when I went to start my pickup to return the engine would not turn over. On the third attempt, it finally started, but smelled like a motor burning up. I was proceeding up a hill and was approaching a stop sign. When I pressed on the brakes, there were no brakes. I could not stop the truck at the stop sign. I coasted through the stop sign at approximately 10mph and I pulled right into a parking lot. No matter how hard I pressed the brake pedal I couldn't get the truck to stop completely so I put the transmission into park. I then proceeded to call for help. When the mechanic arrived, he found that the vacuum hose had come unattached. After speaking with a Ford mechanic over the phone, he stated that the mechanic had since several trucks in the same make and model as mine that also had this same problem occur. At this time, my truck is in the process of being fixed by the mechanic who told us of this problem.

- Colorado City, TX, USA

problem #8

Jun 282005

F-150 4WD 8-cyl

  • Automatic transmission
  • miles
Bad vibration from rear of truck 55-60 mph intermittent. Ford state it is aftermarket tires. Had truck in 2 times with factory tires and 3 times with new tires for same vibration. Pinion angle changed twice on truck causing more vibrations that Ford won't fix. Now truck is leaking engine oil from rear main. I am afraid to take truck on long trips for fear of driveline failure. Numerous complaints on web of same problem. Why is Ford not made to fix this issue?truck has 6,200 miles on it and almost a year old. This could be a big safety concern if driveline failure occurs at highway speeds. I have been an auto mechanic for 18 years at dealerships and I know a tire vibration from a driveline vibration.

- Redford, MI, USA

problem #7

Mar 172006

F-150 4WD 8-cyl

  • Automatic transmission
  • 15,420 miles
: 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.

- Clemmons, NC, USA

Read the next 6 complaints »

Not what you are looking for?