Two problems related to manifold/header/muffler/tail pipe have been reported for the 2005 Ford F-250. The most recently reported issues are listed below.
The contact owns a 2005 Ford F-250. The contact stated the fumes enter the cabin and make the vehicle occupants dizzy. The vehicle was taken to an authorized dealer and the contact was informed that the bolts for the engine manifold corroded and fractured. The dealer stated that this was a known failure because the bolts were metal and the frame was aluminum. The failure mileage was unknown and the current mileage was 55,000.
Diesel fumes came out of passenger air vents making myself nautious and sick from co2 poisoning. Bought it in to the Ford dealer and service manager smelled the problem, said that there might be a problem with the y flange on exhaust manifold. Called back and pulled manifold and didnt see a problem was going to order a new one. Says not an uncommon problem.