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2005 Ford F-350

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By Research the Car 5 min read

The 2005 Ford F-350 Super Duty is a heavy-duty pickup truck known for its robust capabilities and towing capacity. It was available with several engine and transmission options. The most common engine options were the 5.4L Triton V8 (300 hp, 365 lb-ft of torque), the 6.8L Triton V10 (355 hp, 455 lb-ft of torque) and the 6.0L Power Stroke Turbo Diesel V8 (325 hp, 570 lb-ft of torque). The available transmissions were a 5-speed manual or a 5-speed automatic. Owners often praised the F-350 for its workhorse capabilities and solid construction, while common complaints revolved around the 6.0L diesel’s reliability and overall fuel economy.

Engine

5.4L Triton V8

  • Spark Plug Issues
    • Description/Symptoms: Spark plugs breaking upon removal, leading to difficult and costly repairs. Often occurs during routine maintenance.
    • Solution: Using specialized tools and techniques for spark plug removal, potentially requiring professional assistance.
    • Estimated Cost to Fix: $200 - $1000+ (depending on the number of broken plugs and the need for head repair).
    • Recalls: None Found
  • Manifold Leaks
    • Description/Symptoms: Exhaust manifold leaks due to warping or cracking, resulting in a ticking noise, especially upon cold start.
    • Solution: Replacement of the exhaust manifold, often including new gaskets and hardware.
    • Estimated Cost to Fix: $300 - $600+
    • Recalls: None Found

6.8L Triton V10

  • Spark Plug Issues
    • Description/Symptoms: Similar to the 5.4L, spark plugs are prone to breaking upon removal.
    • Solution: Employing specialized tools and techniques, often requiring a professional mechanic.
    • Estimated Cost to Fix: $300 - $1200+ (due to the greater number of plugs).
    • Recalls: None Found
  • EGR valve failure
    • Description/Symptoms: Rough idling or stalling, check engine light with EGR codes, and poor fuel economy.
    • Solution: Replacing the EGR valve.
    • Estimated Cost to Fix: $200 - $400+
    • Recalls: None Found

6.0L Power Stroke Turbo Diesel V8

  • EGR Cooler Failure
    • Description/Symptoms: Coolant loss, white smoke from the exhaust, and potential for overheating.
    • Solution: Replacing the EGR cooler with an updated design.
    • Estimated Cost to Fix: $800 - $1500+
    • Recalls: None Found
  • Oil Cooler Failure
    • Description/Symptoms: Overheating, oil in the coolant, and reduced engine performance.
    • Solution: Replacing the oil cooler, often requiring coolant flush and potential oil change.
    • Estimated Cost to Fix: $500 - $1200+
    • Recalls: None Found
  • High-Pressure Oil Pump (HPOP) Failure
    • Description/Symptoms: Hard starting, stalling, and reduced engine power.
    • Solution: Replacing the HPOP, sometimes including related components like the IPR valve.
    • Estimated Cost to Fix: $800 - $2000+
    • Recalls: None Found
  • Fuel Injector Issues
    • Description/Symptoms: Rough idling, misfires, white smoke, and decreased fuel economy.
    • Solution: Replacing faulty fuel injectors. Often recommended to replace all injectors at once.
    • Estimated Cost to Fix: $300 - $600+ per injector, $1800 - $3600+ to replace all
    • Recalls: None Found
  • Head Gasket Failure
    • Description/Symptoms: Overheating, coolant loss, white smoke from the exhaust, and potential for coolant entering the oil.
    • Solution: Replacing head gaskets, often requiring machining of the cylinder heads.
    • Estimated Cost to Fix: $3000 - $6000+
    • Recalls: None Found

Transmission

5R110W TorqShift 5-Speed Automatic Transmission (All Engine Options)

  • Torque Converter Failure
    • Description/Symptoms: Shuddering during acceleration, slippage between gears, and abnormal noises.
    • Solution: Replacing the torque converter, often including a transmission fluid flush and filter replacement.
    • Estimated Cost to Fix: $800 - $2000+
    • Recalls: None Found
  • Valve Body Issues
    • Description/Symptoms: Hard or erratic shifting, delayed engagement, and slipping between gears.
    • Solution: Replacing or rebuilding the valve body.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found
  • Transmission Overheating
    • Description/Symptoms: Transmission slipping, hard shifting, or complete failure, often accompanied by a transmission temperature warning light.
    • Solution: Inspecting and potentially replacing the transmission cooler, verifying proper fluid level, and addressing any underlying issues like torque converter failure or valve body problems.
    • Estimated Cost to Fix: $200 - $1000+ (depending on the cause and components replaced).
    • Recalls: None Found

Suspension

  • Ball Joint Failure
    • Description/Symptoms: Front end noise, clunking while turning or going over bumps, and uneven tire wear.
    • Solution: Replacing the worn ball joints, often requiring alignment after the repair.
    • Estimated Cost to Fix: $300 - $800+ per side.
    • Recalls: None Found
  • Leaf Spring Sagging/Cracking
    • Description/Symptoms: Rear end sagging, reduced load capacity, and potential for cracking in the leaf springs.
    • Solution: Replacing the leaf springs, potentially including new U-bolts and hardware.
    • Estimated Cost to Fix: $500 - $1500+ per side.
    • Recalls: None Found

Electrical

  • Instrument Cluster Issues
    • Description/Symptoms: Erratic gauge readings, flickering lights, and potential for complete cluster failure.
    • Solution: Repairing or replacing the instrument cluster.
    • Estimated Cost to Fix: $300 - $800+
    • Recalls: None Found
  • Glow Plug Control Module (GPCM) Failure (6.0L Diesel)
    • Description/Symptoms: Hard starting, especially in cold weather, and a check engine light.
    • Solution: Replacing the GPCM.
    • Estimated Cost to Fix: $200 - $500+
    • Recalls: None Found

Exterior

  • Rust (especially around wheel wells and rocker panels)
    • Description/Symptoms: Visible rust, bubbling paint, and potential for structural damage in severe cases.
    • Solution: Rust repair, body panel replacement, and repainting.
    • Estimated Cost to Fix: $300 - $3000+ (depending on the severity and area affected)
    • Recalls: None Found

Interior

  • Blend Door Actuator Failure
    • Description/Symptoms: Inconsistent HVAC temperatures, clicking noises behind the dashboard, and inability to control air flow.
    • Solution: Replacing the faulty blend door actuator(s).
    • Estimated Cost to Fix: $200 - $500+
    • Recalls: None Found
  • Seat Problems
    • Description/Symptoms: Broken frames, torn material, and non-functional power adjustments.
    • Solution: Replacement or repair of seat components, including frames, covers, or power motors.
    • Estimated Cost to Fix: $200 - $1000+ (depending on the severity and extent of repair).
    • Recalls: None Found

Summary

The 2005 Ford F-350, while a capable truck, has its share of common issues. The 6.0L Power Stroke diesel is particularly prone to problems, including EGR cooler, oil cooler, and head gasket failures, which can lead to significant repair costs. The 5.4L and 6.8L Triton engines are not without issues either. The 5R110W transmission, found across all engine options, can experience torque converter and valve body problems. Owners should also be aware of potential suspension wear and electrical issues. Overall, prospective buyers should carefully inspect any 2005 F-350 and be prepared for potential repairs, especially on diesel models. The severity of these issues ranges from minor inconveniences to major mechanical failures, with repair costs ranging from a few hundred dollars to several thousand.

Ford, F-350
Ford F-350 2005
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