2005 Ford E-350 Super Duty

Here’s a comprehensive list of common issues and complaints for the 2005 Ford E-350 Super Duty, organized by category and engine/transmission option. This information aims to provide accurate and detailed insights to potential buyers.

The 2005 Ford E-350 Super Duty is a popular van known for its durability and versatility, often used for commercial purposes, conversions, and hauling. Available engine options include the 5.4L Triton V8, the 6.8L Triton V10, and the 6.0L Power Stroke Turbo Diesel V8. The 5.4L V8 produces around 255 horsepower and 350 lb-ft of torque. Owners often appreciate the van’s spaciousness and towing capacity, but some common complaints include its fuel economy, ride quality, and potential for costly repairs, especially with the diesel engine. A 4-speed automatic transmission was standard.

Engine

5.4L Triton V8

• Spark Plug Thread Issues
  • Description/Symptoms: Spark plugs can become seized in the cylinder head, leading to thread damage or complete stripping when attempting removal. This often results in blown-out spark plugs.
  • Solution: Use penetrating oil, extract damaged plugs with specialized tools, and potentially repair or replace the cylinder head.
  • Estimated Cost to Fix: $200 - $1500+ (depending on the severity and repair method)
  • Recalls: None Found
• EGR Valve Failure
  • Description/Symptoms: Rough idle, poor performance, check engine light illuminated.
  • Solution: Replace the EGR valve.
  • Estimated Cost to Fix: $150 - $350
  • Recalls: None Found

6.8L Triton V10

• Spark Plug Thread Issues
  • Description/Symptoms: Similar to the 5.4L, spark plugs are prone to seizing and damaging the threads in the aluminum cylinder heads upon removal. This often results in blown-out spark plugs.
  • Solution: Use penetrating oil, extract damaged plugs with specialized tools, and potentially repair or replace the cylinder head.
  • Estimated Cost to Fix: $200 - $1500+ (depending on the severity and repair method)
  • Recalls: None Found
• Exhaust Manifold Leaks
  • Description/Symptoms: Ticking noise, especially when cold, diminishing as the engine warms up. Decreased fuel efficiency.
  • Solution: Replace the exhaust manifold and potentially any broken studs.
  • Estimated Cost to Fix: $300 - $800
  • Recalls: None Found

6.0L Power Stroke Turbo Diesel V8

• EGR Cooler Failure
  • Description/Symptoms: Coolant loss, white smoke from the exhaust, overheating.
  • Solution: Replace the EGR cooler. Upgrade to a bulletproof EGR cooler to prevent future failure.
  • Estimated Cost to Fix: $800 - $2000+ (depending on the type of EGR cooler and labor costs)
  • Recalls: None Found
• Injector Failure
  • Description/Symptoms: Rough running engine, excessive smoke, poor fuel economy.
  • Solution: Replace the faulty injectors.
  • Estimated Cost to Fix: $400 - $800+ per injector.
  • Recalls: None Found
• High-Pressure Oil Pump (HPOP) Failure
  • Description/Symptoms: Hard starting, stalling, or no-start condition.
  • Solution: Replace the HPOP.
  • Estimated Cost to Fix: $800 - $1800
  • Recalls: None Found
• Oil Cooler Failure
  • Description/Symptoms: Oil in the coolant, coolant in the oil, overheating.
  • Solution: Replace the oil cooler.
  • Estimated Cost to Fix: $600 - $1500
  • Recalls: None Found

Transmission

4R75E 4-Speed Automatic

• Transmission Slipping/Harsh Shifting
  • Description/Symptoms: Delayed engagement, slipping between gears, harsh shifts, especially when hot.
  • Solution: Perform a transmission service, replace the valve body, or rebuild/replace the transmission.
  • Estimated Cost to Fix: $200 (service) - $3000+ (rebuild/replace)
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, stalling, or complete loss of power transfer.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $500 - $1200
  • Recalls: None Found

Suspension

• Worn Ball Joints
  • Description/Symptoms: Clunking noise from the front end, uneven tire wear, loose steering.
  • Solution: Replace the ball joints.
  • Estimated Cost to Fix: $300 - $800 per side
  • Recalls: None Found
• Worn Leaf Springs
  • Description/Symptoms: Sagging rear end, poor ride quality, reduced load capacity.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $400 - $1000 per side
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming lights, battery not charging, stalling.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• GEM (Generic Electronic Module) Issues
  • Description/Symptoms: Intermittent electrical problems, such as door locks, power windows, or lighting malfunctions.
  • Solution: Diagnose and potentially replace the GEM.
  • Estimated Cost to Fix: $300 - $800
  • Recalls: None Found

Exterior

• Rust (Body and Frame)
  • Description/Symptoms: Rust forming on body panels, especially around wheel wells and seams. Frame rust can compromise structural integrity.
  • Solution: Treat rust with rust converters and paint, or replace rusted panels. Frame rust repair can be extensive.
  • Estimated Cost to Fix: $100 - $Thousands (depending on severity)
  • Recalls: None Found

Interior

• Cracked Dashboard
  • Description/Symptoms: Dashboard cracking, particularly in warmer climates.
  • Solution: Replace the dashboard or install a dashboard cover.
  • Estimated Cost to Fix: $200 - $800
  • Recalls: None Found
• Headliner Sagging
  • Description/Symptoms: Headliner material detaching from the backing and sagging down.
  • Solution: Replace the headliner.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found

Summary

The 2005 Ford E-350 Super Duty, while a capable and versatile van, has its share of common issues. The spark plug thread issues with the gasoline engines and the problems with the 6.0L diesel are particularly significant, often leading to expensive repairs. Transmission issues and suspension wear are also common concerns. Rust is a major issue on these vans depending on the area the vehicle is located. Potential buyers should be aware of these potential problems and carefully inspect any used E-350 before purchase. The severity and cost of these issues can range from relatively minor to quite substantial, depending on the specific problem and the extent of the damage.