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2005 Ford F-250

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By Research the Car 5 min read

The 2005 Ford F-250 Super Duty is a popular work truck known for its robust capabilities and towing capacity. Available engine options included the 5.4L Triton V8, the 6.8L Triton V10, and the formidable 6.0L Power Stroke diesel V8. The 6.0L Power Stroke produced 325 horsepower and 560 lb-ft of torque. It was offered with either a 5-speed manual or a 5-speed automatic transmission. Owners often praise the truck’s ability to handle heavy loads and its overall durability. However, common complaints revolve around the reliability of the 6.0L diesel engine, particularly issues with the EGR system and head gaskets, and the overall cost of maintaining a heavy-duty truck.

Engine

6.0L Power Stroke Diesel V8

  • EGR Cooler Failure
    • Description/Symptoms: Overheating, coolant loss, white smoke from exhaust, possible engine damage if not addressed quickly.
    • Solution: Replace the EGR cooler with an upgraded aftermarket version or a revised OEM part.
    • Estimated Cost to Fix: $800 - $1500+
    • Recalls: None Found
  • Head Gasket Failure
    • Description/Symptoms: Overheating, coolant loss, white smoke from exhaust, “puking” coolant from the degas bottle (coolant reservoir). Often caused by stretched head bolts.
    • Solution: Replace head gaskets, install ARP head studs, and potentially machine the cylinder heads to ensure proper sealing.
    • Estimated Cost to Fix: $3000 - $6000+
    • Recalls: None Found
  • Injector Failure
    • Description/Symptoms: Misfires, rough idling, poor fuel economy, black smoke from exhaust.
    • Solution: Replace faulty injectors. It’s often recommended to replace all injectors at once to ensure consistent performance.
    • Estimated Cost to Fix: $2000 - $4000+
    • Recalls: None Found
  • High Pressure Oil Pump (HPOP) Failure
    • Description/Symptoms: Hard starting, no start condition, poor performance, stalling.
    • Solution: Replace the HPOP.
    • Estimated Cost to Fix: $1000 - $2500+
    • Recalls: None Found
  • Turbocharger Failure
    • Description/Symptoms: Lack of power, excessive black smoke, unusual noises from the turbocharger (whining, screeching).
    • Solution: Replace or rebuild the turbocharger.
    • Estimated Cost to Fix: $1500 - $3000+
    • Recalls: None Found

5.4L Triton V8

  • Spark Plug Breakage During Removal
    • Description/Symptoms: Difficult or impossible spark plug removal, broken spark plugs inside the cylinder head. This is a known issue with the 2004-2008 5.4L 3V engines.
    • Solution: Use a special spark plug removal tool, soak the spark plugs with penetrating oil, and carefully extract the broken pieces. In some cases, the cylinder head may need to be removed for extraction.
    • Estimated Cost to Fix: $300 - $1500+ (depending on the number of broken plugs and the need for head removal)
    • Recalls: None Found
  • Cam Phaser Noise/Failure
    • Description/Symptoms: Rattling noise from the front of the engine, especially at idle or low RPMs, rough idling, reduced power.
    • Solution: Replace the cam phasers, timing chains, chain guides, and potentially the VCT solenoids.
    • Estimated Cost to Fix: $1500 - $3000+
    • Recalls: None Found

6.8L Triton V10

  • Spark Plug Breakage During Removal
    • Description/Symptoms: Difficult or impossible spark plug removal, broken spark plugs inside the cylinder head. This is a known issue with the 2004-2008 5.4L 3V engines.
    • Solution: Use a special spark plug removal tool, soak the spark plugs with penetrating oil, and carefully extract the broken pieces. In some cases, the cylinder head may need to be removed for extraction.
    • Estimated Cost to Fix: $300 - $1500+ (depending on the number of broken plugs and the need for head removal)
    • Recalls: None Found

Transmission

5R110W TorqShift Automatic (Common to all engine options)

  • Valve Body Issues
    • Description/Symptoms: Harsh shifting, slipping between gears, delayed engagement, erratic shifting.
    • Solution: Replace or rebuild the valve body.
    • Estimated Cost to Fix: $800 - $2000+
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Shuddering, vibrations, poor acceleration, complete transmission failure.
    • Solution: Replace the torque converter.
    • Estimated Cost to Fix: $800 - $1500+
    • Recalls: None Found

Suspension

  • Leaf Spring Sag/Failure
    • Description/Symptoms: Reduced ride height, poor ride quality, sagging rear end, especially when loaded.
    • Solution: Replace the leaf springs.
    • Estimated Cost to Fix: $500 - $1500+ (per axle)
    • Recalls: None Found
  • Ball Joint Wear
    • Description/Symptoms: Clunking noises from the front end, loose steering, uneven tire wear.
    • Solution: Replace the worn ball joints.
    • Estimated Cost to Fix: $300 - $800+ (per side)
    • Recalls: None Found

Electrical

  • FICM (Fuel Injection Control Module) Failure (6.0L Diesel)
    • Description/Symptoms: Hard starting, poor performance, stalling, lack of power.
    • Solution: Replace or repair the FICM.
    • Estimated Cost to Fix: $400 - $800+
    • Recalls: None Found
  • Alternator Failure
    • Description/Symptoms: Dimming headlights, dead battery, charging system warning light.
    • Solution: Replace the alternator.
    • Estimated Cost to Fix: $200 - $500+
    • Recalls: None Found

Exterior

  • Rust on Body Panels
    • Description/Symptoms: Rust forming on the wheel wells, rocker panels, and cab corners, especially in areas with harsh winters and road salt.
    • Solution: Repair or replace rusted body panels.
    • Estimated Cost to Fix: Varies greatly depending on the extent of the rust. $500 - $5000+
    • Recalls: None Found

Interior

  • Cracked Dashboard
    • Description/Symptoms: Cracking of the plastic dashboard, especially on the top surface, due to exposure to sunlight and temperature changes.
    • Solution: Replace the entire dashboard, use a dashboard cover, or repair the cracks with a specialized filler.
    • Estimated Cost to Fix: $200-$1500+
    • Recalls: None Found

Summary

The 2005 Ford F-250 can be a capable and reliable truck, but potential buyers should be aware of the common issues, particularly those associated with the 6.0L Power Stroke diesel engine. Head gasket failure, EGR cooler problems, and injector failures can lead to significant repair costs. While the 5.4L V8 and 6.8L V10 are generally more reliable, spark plug issues and cam phaser problems are worth noting. Suspension and electrical issues are also fairly common across the board. Overall, while some problems might be minor, the potential for major engine and transmission repairs makes a thorough inspection crucial before purchasing this truck. The cost of repairs can range from a few hundred dollars for minor issues to several thousand for major engine or transmission overhauls.

Ford, F-250
Ford F-250 2005
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