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2005 Ford F-550 Super Duty

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By Research the Car 5 min read

The 2005 Ford F-550 Super Duty is a heavy-duty work truck known for its robust capabilities and towing capacity. Owners appreciate its solid build and commercial applications, but some dislike its rough ride and dated interior. Engine options include the 5.4L Triton V8, the 6.8L Triton V10, and the 6.0L Power Stroke Turbo Diesel V8. The 6.0L Power Stroke Diesel produces 325 horsepower and 570 lb-ft of torque. Transmission options typically include a 5-speed manual and a 5-speed automatic transmission, depending on the engine. Common complaints revolve around reliability issues with the 6.0L diesel engine, electrical problems, and some suspension components.

Engine

6.0L Power Stroke Turbo Diesel V8

  • EGR Cooler Failure
    • Description/Symptoms: Overheating, coolant loss, white smoke from the exhaust, rough running engine. The EGR cooler cracks internally, allowing coolant to leak into the exhaust system.
    • Solution: Replace the EGR cooler with an updated version or delete the EGR system (check local regulations).
    • Estimated Cost to Fix: $500 - $1500+ depending on the repair shop and parts used.
    • Recalls: None Found
  • Injector Failure
    • Description/Symptoms: Rough running engine, misfires, white smoke from the exhaust, loss of power, fuel dilution in the oil. The injectors in the 6.0L Powerstroke are known to fail causing a range of issues
    • Solution: Replace faulty injectors. It is generally recommended to replace all injectors at once to ensure even fuel delivery.
    • Estimated Cost to Fix: $2000 - $4000+ depending on the number of injectors replaced and the shop’s labor rate.
    • Recalls: None Found
  • High Pressure Oil Pump (HPOP) Failure
    • Description/Symptoms: Hard starting, no starting, stalling, rough running engine. The HPOP provides the high-pressure oil needed to actuate the fuel injectors.
    • Solution: Replace the HPOP. Consider upgrading to an aftermarket HPOP for improved reliability.
    • Estimated Cost to Fix: $800 - $2000+ depending on the part and shop’s labor rate.
    • Recalls: None Found
  • Head Gasket Failure
    • Description/Symptoms: Overheating, coolant loss, white smoke from the exhaust, bubbling in the coolant reservoir, excessive pressure in the cooling system. The 6.0L Power Stroke is prone to head gasket failure due to the high cylinder pressures.
    • Solution: Replace the head gaskets. Studding the heads with aftermarket head studs is highly recommended to prevent future failures.
    • Estimated Cost to Fix: $3000 - $6000+ depending on the repair shop, parts used, and if the heads need to be machined.
    • Recalls: None Found

6.8L Triton V10

  • Spark Plug Issues
    • Description/Symptoms: Misfires, rough running engine, check engine light. The 6.8L V10, like other Triton engines, can have issues with spark plugs breaking upon removal due to the two-piece design.
    • Solution: Use caution when removing spark plugs. Use a specialized tool to help prevent breakage, or have a professional mechanic handle the job. Replacing the spark plugs.
    • Estimated Cost to Fix: $200 - $500+ depending on the number of plugs that break and the mechanic’s labor rate.
    • Recalls: None Found

5.4L Triton V8

  • Spark Plug Issues
    • Description/Symptoms: Misfires, rough running engine, check engine light. The 5.4L V8, like other Triton engines, can have issues with spark plugs breaking upon removal due to the two-piece design.
    • Solution: Use caution when removing spark plugs. Use a specialized tool to help prevent breakage, or have a professional mechanic handle the job. Replacing the spark plugs.
    • Estimated Cost to Fix: $200 - $500+ depending on the number of plugs that break and the mechanic’s labor rate.
    • Recalls: None Found

Transmission

  • Torque Shift 5R110W 5-Speed Automatic
    • Erratic Shifting
      • Description/Symptoms: Harsh shifts, slipping between gears, failure to shift, or hunting for gears. This can be caused by valve body issues or worn internal components.
      • Solution: Valve body replacement or rebuild, transmission replacement.
      • Estimated Cost to Fix: $500 - $4000+ depending on the extent of the damage.
      • Recalls: None Found
    • Torque Converter Failure
      • Description/Symptoms: Shuddering during acceleration, poor fuel economy, overheating.
      • Solution: Torque converter replacement.
      • Estimated Cost to Fix: $800 - $2000+
      • Recalls: None Found No Issues Found for Manual Transmission

Suspension

  • Leaf Spring Sagging/Cracking
    • Description/Symptoms: Vehicle sagging, poor ride quality, reduced load-carrying capacity, visible cracks in the leaf springs.
    • Solution: Replace the leaf springs. Consider upgrading to heavier-duty springs for improved performance and durability.
    • Estimated Cost to Fix: $500 - $1500+ per axle.
    • Recalls: None Found
  • Ball Joint Failure
    • Description/Symptoms: Front-end clunking noise, wandering steering, uneven tire wear, loose steering feel.
    • Solution: Replace the ball joints.
    • Estimated Cost to Fix: $300 - $800+ per side.
    • Recalls: None Found

Electrical

  • Glow Plug Issues (Diesel)
    • Description/Symptoms: Hard starting in cold weather, excessive smoke on startup, rough running engine. The glow plugs assist in starting the diesel engine in cold conditions.
    • Solution: Replace the faulty glow plugs and/or the glow plug control module.
    • Estimated Cost to Fix: $200 - $600+
    • Recalls: None Found
  • Alternator Failure
    • Description/Symptoms: Dimming headlights, warning lights on the dash, dead battery, inability to start the vehicle.
    • Solution: Replace the alternator.
    • Estimated Cost to Fix: $200 - $500+
    • Recalls: None Found

Exterior

  • Rust on Body Panels
    • Description/Symptoms: Rust forming on the rocker panels, cab corners, and wheel wells, especially in regions with salt usage.
    • Solution: Rust repair or panel replacement.
    • Estimated Cost to Fix: $300 - $2000+ depending on the severity of the rust and the extent of the repair.
    • Recalls: None Found

Interior

  • Cracked Dashboard
    • Description/Symptoms: Cracking and splitting of the dashboard, especially in vehicles exposed to high temperatures.
    • Solution: Dashboard replacement or use of a dashboard cover.
    • Estimated Cost to Fix: $200 - $1000+ depending on the solution chosen.
    • Recalls: None Found

Summary

The 2005 Ford F-550 Super Duty is a capable work truck, but owners should be aware of potential issues, particularly with the 6.0L Power Stroke diesel engine. EGR cooler failure, injector problems, and head gasket issues are common and can be costly to repair. Electrical problems such as glow plug issues and alternator failures can also occur. Suspension issues such as sagging leaf springs and ball joint failure are also common due to the heavy-duty nature of the vehicle. The severity of these issues ranges from moderate to significant, and the cost of repairs can vary widely depending on the problem and the repair shop.

Ford, F-550 Super Duty
Ford F-550 Super Duty 2005
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