Body problems of the 2005 Ford F-150

This is an extended cab - 4 door - the rear doors are half doors with a a handle allowing entry and exit to and from the rear passenger seats. (it is not a crew cab 4 door). The doors locked and the handles failed with a child in the rear seat. The doors cannot be opened. The child and his mother had to climb over the center console to exit the vehicle. The vehicle is at a mechanic who states no part are available to repair this faulty and unsafe door mechanism. Both rear doors are locked. Qualified mechanic estimates the cost to rig a fix, in absence of any left door mechanism parts will be near or over $500. 00. The mechanic reports that the control cables from the handles to the door latch stretched and failed. If there had been a collision or engine fire, rear seated passengers would be trapped inside the vehicle. This needs to be addressed and repaired by Ford.

Frame on passenger and drive side by transmission, fuel tank, and rear leaf springs are rusted and have no integrity left. No structure integrity if in an accident. If fractures completely, will loose control of vehicle as the bed will contact cab, driveshaft will jamb into transmission, lock up brakes from pinched brake lines, loss of brakes from severed brake lines, lose control and go into on coming traffic or into roadside structures including pedestrians. Note: your system will not let me upload pictures.

The whole frame is rusting out and the bed dipped and looks like it will fold in half.

Truck frame is rotting from the inside out, could not tell the extent of damage from looking underneath, I have to get it repaired before it snaps in half.

Frame started rusting through frame the inside out, first discovered in 2021. I had to have the frame repaired with no help from Ford in October of 2022.

This and many other trucks of this generation have major frame rot issues due to the box frame. The rest of my truck looks excellent but the frame is so bad its most likely not repairable. I am not the only one with this major safety issue. Its only a 16 year old truck. Thankfully I have not towed or put a large load in the bed or else it could split in half. I wash my car seasonally and pressure wash off rust every spring. Yet the frame has rotted so badly they could not put it on a lift to do the alignment. I love this truck and I'm a big fan of the f150 line as a whole. Ford should take responsibility as Toyota has and fix their customers frames from this generation. I love Ford but its always interesting walking through a parking lot and seeing every 04-08 f150 with major frame rot. Without fail every single one has that issue. Seems to me like they didn't properly galvanize and protect the steel. I am now needing to do a bed off frame restoration since no shop will take it on. This truck that should be going for $5k with this insane used car market. (August 3rd 2020) yet it is max $200 in scrap. Bad / cheap engineering should not be the owners responsibility. Yet that is what it has come to. It was most likely an honest unforseen mistake on their part. Overengineering the rigidity but ignoring the long term effects. Short term strength for log term pain as is commonly said with these trucks. I'm sure in a few years time these will just start breaking in half over bumps on the freeway. I beg and encourage Ford to fix this before people die. I doubt Ford wants another pr fiasco like the pinto. Hopefully they will do a cost analysis and realize that a recall is a much better option. Seem like 250-500k a pop for settlements for the most popular truck of all time is much much more than 5k per affected vehicle. Not including the long term dip in sales. So unless they want the other brands to win the truck war they gotta fix it. Tldr: a recall is cheaper than death.

Tl the contact owns a 2005 Ford F-150. The contact stated that he learned that his vehicle was severely rusted on the passenger's and driver's side of the vehicle. The vehicle was rusted from the middle of the vehicle to the rear of the vehicle. The contact had taken the vehicle to a certified mechanic as well as two body shops who stated that the entire subframe needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the issue. The approximate failure mileage was 76,000.

Complete frame under trunk is rusted to where the frame is getting ready to break in half I have looked at several other of the same make and model and they have the same similar problems so I'm not as bad as others but 90% of them are not safe to drive I live in the area there's not a lot of salt nore sand if this was a problem with just my vehicle I would understand but since it is a problem with a lot of these trucks something needs to be done buy Ford manufactures.

Had vehicle towed to a repair garage to have starter replaced. According to repair tech. While lifting truck a lot of cracking sound s inspection of frame reviled excessive rusting and cracks . They called and told me truck was un safe to use. Have bills with statements made by repair shop.

Tl the contact owns a 2005 Ford F-150. The contact stated that the vehicle was taken to an independent mechanic to have front and rear shocks installed. The mechanic informed the contact that due to the severe rust damage to the subframe, it was not recommended to have the shocks replaced. The contact was informed that the vehicle would not pass state inspection within the next few months. The vehicle was not repaired. The dealer and manufacturer were not notified of the failure. The approximate failure mileage was 180,000.

Tl the contact owns a 2005 Ford F-150. While driving 55 mph, the rear frame detached and was rotted out. There were no warning indicators illuminated. The vehicle was taken to tony betten and sons Ford (3839 plainfield Ave ne, grand rapids, mi 49525, (616) 363-6841), but was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the local dealer. The failure mileage was 151,678.

Two mechanics and one autobody technician inspected the truck and reported that the chassis is heavily corroded throughout for the vehicle's age and is not safe for towing. One mechanic reported that the rear end of the truck would require over $1,000 of welded steel reinforcements to make truck towe worthy. Also gas tank can fell due to the tank holder streeps are attached to the corroted chassis.

This vehicle is part of the now famous frame rust issue on 2004 - 2008 F-150 extended cab pickup trucks. This is a one owner well maintained, very clean vehicle in perfect running order. During regular service, I found rust spots on the frame. The rust appeared to be from the inside out. After further investigation the frame had been destroyed by internal rust. I condemned the vehicle and took it off the road. Further investigation showed this was a very widely known problem and contested issue. I have undercoated this truck many times over the years and it was very clean. I. Have never received any notice from Ford about this well documented problem. I am in the process of repairing the frame via dorman products. Ford should be held to account any pay for this repair.

Paint on the roof and back of the cab is flaking off.

Tl- the contact owns a 2005 Ford F-150. The contact stated that while driving approximately 30 mph the exhaust pipe had broke off the vehicle. The vehicle was taken to an independent mechanic who discovered that the entire sub frame of the vehicle had rusted and corroded including the damaged exhaust pipe. The exhaust pipe was repaired but the sub frame was not. The manufacturer was notified of the failure but the local dealer was not. The VIN was not available. The failure mileage was 70,000. Jft.

Frame on my 2005 F-150 is rotted and has become a safety concern.

There is a current recall for this same issue but its till 2004, but should be expanded. I have a 2005 f150 with the same issues as a 2004 f150 and the chassis suffers from massive corrosion. My truck is deemed unsafe to drive. The frame is rotting through and very dangerous to drive. It can separate at any time. The truck only has 88k miles and it could separate at anytime. If involved in an accident it can be fatal. Nhtsa you need to investigate and recall this serious issue right away and save peoples lives.

I have a 2005 f150 fx4 that I bought in 2010. In 2017 with the truck being 12 years old. I had to remove the vehicle from the road because of frame rot! this was my baby and taken well care of. Both sides in front of the rear axle are rotted out to the point a jack just goes right through them. The inspection failed because if they would have lifted it, it would have folded in half. Also has a broken front left coil spring. I should have a vehicle worth around 8-10 grand that is going to sell for scrap metal priced. Why are american auto maker not held responsible for making defective vehicles? my previous vehicle was an 199o Toyota tacoma that had a frame rot recall and mine was spotless. Fast forward, bought an american made vehicle that cost me 15 grand and got 6 and a half years out of and no one holding Ford responsible! sickening!.

Ford f 150 cracked rear frame rails truck made in 2004 they had a recall for trucks made in 2004 but my truck is titled as a 2005 they must still have had bad frames left over they used to build 2005 trucks rear of truck is floating when you drive it.

Vehicle went into "failsafe" mode on two separate occasions within the last year! and most recently, two weeks ago! both at highway speed on two different interstates in florida! very dangerous, and hard to control vehicle to "limp" to a safe place to stop! many possible causes from electrical, fuel, or engine issues that are well documented on many internet sites and f150 forums! also rust issues on roof of vehicle in rain channels! very common,and very poor design!.

The contact owns a 2005 Ford F-150. While the vehicle was at the dealer for maintenance, the contact was informed that the subframe displayed excessive corrosion. The contact was informed that the vehicle was unsafe and should not be driven. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 39,000. The VIN was not available.

Took my truck in for service (engine light on for the oxygen sensor) and when they put the truck on the lift the frame folded because it had rusted out on both sides. I was still driving this truck at highway speeds. I bought the truck new and it was driveway parked in connecticut for the 12 years I have owned it. The mileage on the truck is a little over 40k and the body parts of the truck look very good. I had to scrap the truck for parts, very sad. Someone should notify other owners of the 2005 f150s to check the frames because I had no idea it was this bad.

I own a 2005 Ford F-150 4x4 extended cab with just over 60,000 mi. For its age, the truck is in pretty nice shape except for the frame, it's gone, rusted! there is a section between the cab & engine bay that you can put your fingers through, not one but several fingers, let alone in other areas though out the frame that are also rotted through. It's a boxed frame with no inside coating made with what I read elsewhere was cheep steel, won't mention where from, but not us steel. Yes I live in ne, and it has tasted salt from the roads, but I also kept it clean all winter long. I paid a lot for this truck, bought it new and now feel that I have been cheated. I am now on my third new Ford truck, a 2018, and I'm afraid to walk buy it with a salt shaker in my hand. My first was a 1984 f-250 that I drove for 21 years, put 100,000 miles on it, sold it in 05, and is still on the road to this day on it's third owner. I know where it lives. I'm reading on line that this is happening to a lot of these trucks, let alone I believe Ford has already replaced frames in a Mini van for this same reason. I also have a few pictures. There is a pic just showing the underside, which for the most part is in good shape, a little surface rust, no through rot. Now the frame pics, another story. These trucks also have an issue with the exhaust manifold as to where the bolts holding it in place rot out and now you have a noisy exhaust leak truck that has to have its motor taken out to have that repaired, got that going on also. Thank you for your time, from a not so happy Ford owner when I bought my new truck, Nov of 2017, they evaluated my 05 for a trade in, which I wasn't going to do anyway, they only offered me $3000 on what I thought was a good truck, foiled again!.

Frame on drivers side is rotting away.

Front end collision into the rear of another truck. Whole front end damaged through radiator, hood, headlights, bumpers etc. Airbag never deployed and upon return of vehicle after repairs, I am now getting a code 42 that the sensor is bad and after research find out there is a recall on this but for the opposite reason but also now understand there are corrosion issues with the connection of the sensor also. Hope this helps. Please advise what to do, will Ford fix this whole problem and replace with a new sensor and the wire chaffing problem? thank you in advance!.

When accelerating slowly from a stop light, the drivers side window fell down into the door. Apparently the window regulator broke, an issue which is documented on numerous internet sites. The window dropping into the door created a very distracting driving situation, not to mention visual safety hazards as in today during rainy, foggy, humid conditions affecting the visibility through the remaining glass in the vehicle.

Driving to church on may 6th, 2012 @ 0900 a. M. On the interstate traveling @ 70 mph. I lowered the window about an inch. When I pressed the button to raise the window a loud pop occurred and the window dropped into the door-well. It scared everyone in the truck. It was a sunny day. Potential for loss of life is present with this issue. Inclement weather or blinding debris within the cab could raise the potential for loss of life. Please petition Ford motor company for a recall on this potentially life threatening issue.

The truck was not running. When the door was opened the flames , from the burning seat shot up and burnt the carpet and door panel , before it could be put out. The controls on the seat were completely melted. It still has a smell of an electrical fire.

Poor quality paint on my 2005 Ford F-150. It has begun peeling and exposing the primer.

Passenger side window regulator failure - fell inside door. According to dealer is a very common complaint caused by Ford using cheap plastic clips to secure cables. Had to tape up the window with plastic to proceed home. This is very unsafe and I know that Ford is aware of the problem but refuses to fix this defect because the vehicle is out of warranty. Glass cracked when it fell inside the door. Ford needs to fix this common defect, or at least tell all future customers of this - before they put their money into this shoddy workmanship.

I have a 2005 Ford F-150 fx4 with 48,000 miles. Towards the middle of winter, I noticed that the paint inside of the gas cap door at the bottom edge was starting to peel away from the body. It has progressively gotten worse over the last couple of months and is now visible with the gas door shut. I find this very disappointing considering the truck only has 48,000 miles on it and has been well taken care of.

Dealer did not repair vehicle per the recall notice,no work was done at all. Contacted dealer serv. Mgr. , no attempt to look at vehicle. Called Ford cust serv. Just took info ,no follow-up or call back. Filled out cust card after service was performed noting complaint,no call or attempt to contact me. Talked to a salesperson via email about dealer when approached to buy a truck by sales person, did not report to general mgr. About my issue with his serv. Dept. . Recall was for power brake booster line which fails. No sign of new parts, clamps or disturbed engine compartment dirt, grime,etc. When I brought truck home right after service.