One problem related to gas recirculation valve (egr valve) has been reported for the 2005 Ford Escape Hybrid. The most recently reported issues are listed below.
Over the past 3 years I have had the issue of 'stop safely now' on multiple occasions. These issues didn't start until the mec pump was replaced under a recall. After that my 2005 Escape Hybrid will shut down while driving or not start or cut out the hybrid power and run on engine only. I took it to the local Ford dealership where we have gotten all other service done three times for these issues. They haven't been able to tell me anything, stating only that there are no codes, so no idea where to look. I couldn't understand how the computer can know to tell me to stop driving the car, yet not record a dtc. It happened again on the first warm day of the summer - drove across town, parked it, came back 20 minutes later and it wouldn't start, showing 'stop safely now'. I left it until the next morning and it started right up and I drove it home. I went out and bought scanxl and used my laptop to scan the car. I found p1a10, p1a14, p0a0a, and p0a95. If I can buy some consumer program and find this info, way is Ford telling there are no codes? Ford also replaced the battery fans two years ago, stating they were covered under some recall or warranty. Searching the internet gets me 100's of comments on this stop safely issue with dozens of possible causes depending on the year and model. My scan tool shows a battery voltage of 665 volts, though it's supposed to be a 300 volt battery. The hybrid evaporator temp can range between 220 and 310 degrees f when it's running ok. That can't be normal. I have no idea what's going on and can't get any help from the Ford dealer.