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2005 Ford F650

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By Research the Car 4 min read

Here’s a breakdown of common issues reported for the 2005 Ford F-650, categorized and formatted as requested. The 2005 Ford F-650 is a medium-duty truck popular for its size, towing capacity, and customization options. Engine options included the Caterpillar 3126 diesel (around 300-330 hp and 860 lb-ft of torque) and the Cummins ISB diesel. Transmissions were typically Allison automatics (5- or 6-speed) or manual transmissions (often Eaton-Fuller). Owners often appreciate the F-650’s robust build and capability for commercial use. Dislikes often center on the vehicle’s size, fuel consumption, and overall cost of ownership.

Engine

Caterpillar 3126 Diesel

  • Injector Issues
    • Description/Symptoms: Rough running, misfires, excessive smoke, poor fuel economy, and potential engine failure. Often caused by worn or clogged injectors.
    • Solution: Replace faulty injectors with new or remanufactured units. Ensure proper fuel filtration to prevent future issues.
    • Estimated Cost to Fix: $2,000 - $4,000+ (depending on the number of injectors and shop labor rates)
    • Recalls: None Found
  • Turbocharger Failure
    • Description/Symptoms: Loss of power, excessive black smoke, loud whistling noises, and potential engine damage if debris enters the engine.
    • Solution: Replace the turbocharger with a new or remanufactured unit. Inspect and clean the intercooler and intake system.
    • Estimated Cost to Fix: $1,500 - $3,000+
    • Recalls: None Found

Cummins ISB Diesel

  • Lift Pump Failure
    • Description/Symptoms: Hard starting, stalling, low power, and potential damage to the high-pressure fuel injection pump.
    • Solution: Replace the lift pump. Consider upgrading to an aftermarket pump with improved reliability.
    • Estimated Cost to Fix: $500 - $1,200
    • Recalls: None Found
  • EGR Valve Issues
    • Description/Symptoms: Poor fuel economy, rough idle, black smoke, and potential for the check engine light to illuminate.
    • Solution: Clean or replace the EGR valve. Inspect and clean the EGR cooler.
    • Estimated Cost to Fix: $300 - $800
    • Recalls: None Found

Transmission

Allison Automatic (5- or 6-Speed)

  • Shift Solenoid Failure
    • Description/Symptoms: Erratic shifting, harsh shifting, failure to shift into certain gears, or getting stuck in gear.
    • Solution: Replace the faulty shift solenoid(s). Perform a transmission service, including filter replacement.
    • Estimated Cost to Fix: $500 - $1,500
    • Recalls: None Found
  • Torque Converter Issues
    • Description/Symptoms: Shuddering, slipping, overheating, and reduced fuel economy.
    • Solution: Replace the torque converter. Inspect the transmission for further damage.
    • Estimated Cost to Fix: $1,500 - $3,000+ (may require transmission rebuild)
    • Recalls: None Found

Eaton-Fuller Manual

  • Clutch Failure
    • Description/Symptoms: Slipping, difficulty shifting, grinding noises, or inability to engage gears.
    • Solution: Replace the clutch disc, pressure plate, and throwout bearing. Consider resurfacing the flywheel.
    • Estimated Cost to Fix: $1,200 - $2,500+
    • Recalls: None Found
  • Shift Linkage Problems
    • Description/Symptoms: Difficulty shifting, imprecise shifting, or inability to select certain gears.
    • Solution: Adjust or replace worn or damaged shift linkage components (rods, bushings, etc.).
    • Estimated Cost to Fix: $200 - $800
    • Recalls: None Found

Suspension

  • Leaf Spring Sagging/Cracking
    • Description/Symptoms: Reduced ride height, poor ride quality, and potential for leaf spring failure.
    • Solution: Replace worn or damaged leaf springs. Consider upgrading to heavy-duty springs for improved load capacity.
    • Estimated Cost to Fix: $800 - $2,000+ (per axle)
    • Recalls: None Found
  • Worn Shocks/Struts
    • Description/Symptoms: Bouncy ride, poor handling, and excessive body roll.
    • Solution: Replace worn shocks/struts.
    • Estimated Cost to Fix: $400 - $1,000+ (per axle)
    • Recalls: None Found

Electrical

  • Battery Drain
    • Description/Symptoms: Dead battery, difficulty starting, and the need for frequent jump starts.
    • Solution: Diagnose and repair the source of the battery drain (e.g., parasitic draw from a faulty component or wiring issue). Replace the battery if necessary.
    • Estimated Cost to Fix: $100 - $500+ (depending on the complexity of the issue)
    • Recalls: None Found
  • Wiring Harness Issues
    • Description/Symptoms: Intermittent electrical problems, malfunctioning lights, sensors, or other electrical components. Often caused by corrosion, chafing, or damaged wiring.
    • Solution: Inspect and repair or replace damaged wiring harness sections.
    • Estimated Cost to Fix: $200 - $1,000+ (depending on the location and extent of the damage)
    • Recalls: None Found

Exterior

  • Rust (Frame and Body)
    • Description/Symptoms: Visible rust on the frame, body panels, and undercarriage. Can lead to structural weakness and corrosion damage.
    • Solution: Remove rust, repair damaged areas, and apply rust-preventative coatings. For severe cases, frame repair or replacement may be necessary.
    • Estimated Cost to Fix: $500 - $5,000+ (depending on the severity of the rust)
    • Recalls: None Found
  • Door Handle Breakage
    • Description/Symptoms: Door handle breaks off or malfunctions, preventing the door from opening or closing properly.
    • Solution: Replace the broken door handle.
    • Estimated Cost to Fix: $100 - $300
    • Recalls: None Found

Interior

  • HVAC Blower Motor Failure
    • Description/Symptoms: Blower motor stops working, resulting in no airflow from the vents.
    • Solution: Replace the blower motor.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found
  • Instrument Cluster Issues
    • Description/Symptoms: Gauges malfunction, display goes blank, or warning lights illuminate incorrectly.
    • Solution: Repair or replace the instrument cluster.
    • Estimated Cost to Fix: $300 - $800+
    • Recalls: None Found

Summary

The 2005 Ford F-650, while a robust and capable truck, does have some common issues. Engine and transmission problems, especially related to the diesel engines and Allison transmissions, tend to be the most expensive to address. Rust is also a significant concern in some regions. The severity and cost of repairs can vary greatly depending on the specific issue and the overall condition of the vehicle. Potential buyers should thoroughly inspect any used F-650 and consider a pre-purchase inspection by a qualified mechanic familiar with medium-duty trucks.

Ford, F650
Ford F650 2005
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