2005 Ford F750

2005 Ford F750

Overview

The 2005 Ford F-750 is a heavy-duty commercial truck known for its robust construction and capability in demanding applications. Reliability for this model year is generally considered strong, particularly in its core mechanical components. However, like any commercial vehicle, specific issues can arise depending on usage, maintenance, and the particular powertrain configuration. This analysis focuses on documented common problems beyond routine maintenance, providing insights into potential areas of concern for owners and fleet managers.

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Engine

7.2L Caterpillar C7 Diesel

Fuel Injector Problems

• Symptoms: Rough idling, loss of power, increased exhaust smoke, poor fuel economy.
• Solution: Replacement of faulty fuel injectors.
• Cost: $800 - $1500 per injector

EGR System Issues

• Symptoms: Check engine light, reduced engine performance, black smoke.
• Solution: Cleaning or replacement of EGR valve and cooler.
• Cost: $500 - $1200

5.9L Cummins ISB Diesel

Fuel Pump Failure

• Symptoms: Engine stalling, difficulty starting, loss of power.
• Solution: Replacement of the fuel lift pump.
• Cost: $400 - $700

Turbocharger Issues

• Symptoms: Loss of power, excessive smoke, whistling noises.
• Solution: Repair or replacement of the turbocharger.
• Cost: $1000 - $2500

6.0L Power Stroke Diesel

Head Gasket Failure

• Symptoms: Coolant loss, white smoke from exhaust, overheating, coolant in oil.
• Solution: Replacement of head gaskets and often head studs.
• Cost: $2500 - $5000+

EGR Cooler Failure

• Symptoms: Coolant leaks, white smoke, overheating.
• Solution: Replacement of the EGR cooler.
• Cost: $600 - $1200

Transmission

Allison 2000 Series (Automatic)

Torque Converter Issues

• Symptoms: Slipping gears, shuddering, delayed engagement.
• Solution: Rebuild or replacement of the torque converter.
• Cost: $1500 - $3000

Allison 3000 Series (Automatic)

Transmission Fluid Leaks

• Symptoms: Visible fluid leaks, shifting problems, overheating.
• Solution: Repair or replacement of seals and gaskets.
• Cost: $300 - $800

Eaton Fuller Manual Transmissions (e.g., FS-5406A, RTLO-8918B)

Clutch Actuator Problems

• Symptoms: Difficulty shifting, stiff clutch pedal.
• Solution: Replacement of the clutch actuator or related components.
• Cost: $500 - $1500

Suspension

Heavy-Duty Leaf Spring Suspension

Leaf Spring Breakage

• Symptoms: Sagging rear end, uneven ride height, clunking noises.
• Solution: Replacement of broken leaf springs.
• Cost: $400 - $1000 per axle

Air Suspension (if equipped)

Air Bag Leaks

• Symptoms: Vehicle sagging on one side, uneven ride height, compressor running excessively.
• Solution: Repair or replacement of leaking air bags.
• Cost: $300 - $700 per bag

Electrical

Wiring Harness

Corrosion and Wear

• Symptoms: Intermittent electrical failures, warning lights, non-functional accessories.
• Solution: Inspection, cleaning, and repair or replacement of damaged sections of the wiring harness.
• Cost: $300 - $1000+

Alternator

Failure

• Symptoms: Battery warning light, dimming lights, engine not charging.
• Solution: Replacement of the alternator.
• Cost: $400 - $800

Exterior

Body Panels and Frame

Rust and Corrosion

• Symptoms: Visible rust, particularly in areas exposed to salt and moisture; potential frame weakening.
• Solution: Rust treatment, panel replacement, or frame repair (depending on severity).
• Cost: $200 - $5000+ (highly variable)

Headlights and Taillights

Condensation

• Symptoms: Moisture buildup inside light housings.
• Solution: Sealing or replacement of light assemblies.
• Cost: $100 - $400 per assembly

Interior

HVAC System

Blower Motor Failure

• Symptoms: No airflow from vents, or intermittent airflow.
• Solution: Replacement of the blower motor.
• Cost: $200 - $500

Dashboard Gauges and Controls

Intermittent Malfunctions

• Symptoms: Gauges not reading correctly, warning lights flickering, buttons not responding.
• Solution: Diagnosis and repair/replacement of faulty modules or switches.
• Cost: $300 - $800

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Summary Verdict

The 2005 Ford F-750 demonstrates a generally solid reliability record for a heavy-duty truck, with its core powertrain and chassis components being robust. However, specific engine options, particularly the 6.0L Power Stroke, are known for more significant and costly potential issues like head gasket failures. Transmission reliability is good, with Allison automatics being a strong point, though wear and tear on seals and torque converters can occur. Suspension components, especially leaf springs, can experience issues under heavy load. Electrical system issues often stem from wear and corrosion in wiring harnesses. Owners should be aware of the specific engine’s known weaknesses and ensure diligent maintenance, especially for the EGR and fuel systems on diesel engines. Overall, with proper care and attention to known problem areas, the F-750 can be a dependable workhorse.