Eight problems related to manifold/header/muffler/tail pipe have been reported for the 2005 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2005 Ford F-150 based on all problems reported for the 2005 F-150.
Exhaust manifolds are leaking and causing exhust fumes to enter the vehicle. Truck has aprox 120,000, issue started at around 80,000. It's at the point now where it makes people in the truck sick and it won't pass state inspection. Cam phasers make noises as well. Wo know when this engine will fail. Common problems with the 5. 4 v8 engine. Well documented on the internet.
The vehicle began to smell like raw fuel, particularly at stop signs or intersections. The smell appeared to be coming from the engine bay. Upon disassembly of the intake components of the engine to expose the fuel injection system, it was evident that the fuel rail had begun leaking raw fuel inside the engine bay. The fuel rail developed a speck of corrosion about 2-3mm in diameter on the top surface of the rail. The corrosion evidently penetrated the entire rail and became a pinhole leak. Raw fuel was seen leaking up and out of the pinhole. This happened on the passenger side fuel rail, which is positioned inches away from the high voltage coil pack, and above the exhaust manifold as well. Called Ford customer service hotline and was told there is no recall for it, no extended warranty program, no assistance whatsoever. Ordered a new fuel rail through local Ford dealer for $500 dollars (4 times what a typical fuel rail costs); part has not been shipped, dealer unsure if Ford has any in stock or is even making the part. Truck has been inoperable for over a week with no way to fix it.
Exhaust manifold on the Fords' 5. 4l engine apparently were not engineered correctly. I have heard of many that have leaked and had to be replaced. I worry about the possibility of fire. I have contacted Ford motor CO. Multiple times however they declined any help with there replacement on my truck. It seems to be a very common problem from what I've heard and see online. Should Ford have a recall on these manifolds?.
I was driving to town when engine started making a sound like a large compressor, stopped truck, could feel air coming from the top of the head by intake manifold, took to a garage where I was informed that the plug came out of the #2 cylinder and busted the coil pak. I know this has happened to many f150 truck owners, I know of 3 locally, and have found many more complaints with the same problem. Ford should recall, this problem.
Proceeded to drive out of home driveway onto road, which is gravel and travels immediately downhill. I heard a pop and what sounded like exhaust/compression popping and experienced the engine skipping with slight loss of power. I turned around, as soon as it was safe to do so, and drove back to my own driveway. I contacted a local mechanic which I use regulary and explained my situation. The mechanic was only able to check it out Thursday 8, September, 2011. He then diagnosed the problem as a blown sparkplug and suggested I contact Ford for some relief as the problem is widespread. I did and was denied. The problem, as I understand it, could have resulted in having raw gasoline spraying out of the spark plug hole, onto a hot manifold and possibly causing a fire.
There is a obvious problem with the manifolds on this truck. My truck is an fx4 and rarely seen any off roading. My manifolds are cracked and the truck has been babied this results in a very annoying noise. Also the transmission had be replaced at 30,000 miles under warranty, the new one is still slipping.
While driving, the vacuum solenoid for the 4 wheel drive tries to engage the 4 wheel drive - even at highway speeds- resulting in a horrible sound. The sound was "like I had run over a shopping cart or hit something in the road and was dragging it under the truck". This happened 5 times in two days in less than 30 miles of total driving. The noise is so loud and alarming that it made me immediately apply the brakes and pull to the side of the road because I thought I had hit something/someone. At first I wondered if my muffler or drive shaft or some other part had fallen off of the truck. This "false engagement" of the 4 wheel drive happens without any warning in all kids of driving conditions (slow, fast, breaking or accelerating). A new, redesigned (now has a cover on it to keep moisture out- which was causing the failure) vacuum solenoid was installed on truck - a $27. 00 part. Dealership kept old part. Tech. At dealer told me that this part will go bad at some point and need replacing on all the trucks with the part. He said "not if but when". Ford knew about the problem - hence the redesigned part. Ford has not notified owners of this part and it's impending failure.
Experienced sudden loss of power steering and power brakes while normal and routine driving on highway. No warning of any kind that failure was about to occur. Engine ran rough, engine light warning came on after brake and steering failure and then engine shut off. Narrowly avoided rear end collision and driving off the highway and into steep ravine. Was able to bring vehicle under control with a lot of effort to steer and emergency brake. Could have been injuries and/or fatal. Towed vehicle to Ford dealer. Dealer performed eec test and received codes p0171 and p0174. Dealer found vacuum hose from intake manifold to ebrake booster broken. Dealer removed intake manifold, replaced vacuum hose and intake gaskets, and reinstalled intake manifold and cleared codes. I have old parts.