2005 Ford E-350: common problems

Owners of the 2005 Ford E-350 filed 55 complaints with NHTSA, most often about electrical system and engine and cooling. Details by component below, with sources.

Key figures

Owner complaints: 55
involving a crash: 2

What fails most often

1 Electrical system 31% of all complaints
2 Engine and cooling 29% of all complaints
3 Fuel system 24% of all complaints
4 Engine 9% of all complaints
5 Equipment 9% of all complaints
6 Powertrain 9% of all complaints
7 Service brakes 9% of all complaints
8 Fuel/propulsion system 7% of all complaints

Circle size and colour show each component’s share of NHTSA complaints. Schematic only, not a drawing of the exact model.

Electrical system: 17 complaints (31% of all), 1 of them with a crash reported by the owner.
Engine and cooling: 16 complaints (29% of all).
Fuel system: 13 complaints (24% of all).
Engine: 5 complaints (9% of all).
Equipment: 5 complaints (9% of all).

Symptoms owners describe

How many of the 55 NHTSA complaints mention each symptom (automatic count from complaint text; one complaint can mention several).

stalls while driving13 · 24%
warning lights, check engine13 · 24%
A/C or heater8 · 15%
fuel system, fuel smell7 · 13%
engine failure or replacement6 · 11%
loss of power / limp mode6 · 11%
won't start5 · 9%
brake failure2 · 4%
smoke, burning smell, fire2 · 4%
rollaway, parking brake1 · 2%

Components owners complain about

Component	Owner complaints	involving a crash
Electrical system	17	1
Engine and cooling	16	0
Fuel system	13	0
Engine	5	0
Equipment	5	0
Powertrain	5	0
Service brakes	5	1
Fuel/propulsion system	4	0
Tires	2	0
Suspension	1	0
Visibility	1	0

What owners report

Short excerpts of NHTSA complaints in the original wording. These are owner statements not verified by NHTSA; personal data removed.

Consumer states while pulling into a parking lot and applying the brakes, the van's brakes failed to operate causing a collision the consumer stated the vacuum pump attached to the engine failed. The consumer stated the brake, was a major component that failed and there was no warning of a failure. Update 01/13/14
Service brakes · crash · 2010-12-06 · NHTSA complaint #10368998
Ford 2005 e350 diesel both new still under warranty breakdown over a dozen times wouldn't start sometimes after 20 min. Trying it starts roadside assistance. Tow it 5 times to difference ford certified technician they change parts but same problem it stall once my dad hit a parked truck damage hood and fender I can…
Electrical system · crash · 2007-11-04 · NHTSA complaint #10207884
The contact stated no warning light was illuminated. The contact pulled over and as soon as he exited the vehicle it had become engulfed in flames. The contact stated that the flames came from under the rear of the vehicle.
Fuel system · 2023-11-03 · NHTSA complaint #11553413
Only 87000 miles and the fuel tank is shedding silver paint flakes, into the fuel system.. Have now replaced all the filters twice, pump once.. And the tank pre filter has to be clogged as no fuel will even come out.. Had been a very good truck, but this engineering causes the van to just die!! On the road.
Fuel/propulsion system · 2020-09-14 · NHTSA complaint #11355011
While driving various speeds, the vehicle suddenly stalled. The vehicle was taken to the dealer where it was diagnosed that the fuel injection control module failed. The contact replaced the control module, but the failure continued.
Electrical system · 2016-10-04 · NHTSA complaint #10913614
The contact stated that the heater box failed to change settings after the initial setting. The vehicle was taken to a dealer who diagnosed that the heater box needed to be replaced. The manufacturer was notified of the failure. The vehicle was not repaired. The failure mileage was 42,900.
Visibility · 2015-09-14 · NHTSA complaint #10763509
Tl* the contact owns a 2005 ford e-350. The contact stated that the gear shifter failed to shift. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 243,000.
Powertrain · 2015-04-17 · NHTSA complaint #10706285
It would not start right away, but after letting it sit for 15 minutes, it started and had regained power and I drove it till I got to the nest hill and did the same thing several times till I made it home 3 hours later for a 10 mile trip.
Engine · 2014-11-21 · NHTSA complaint #10659991

When owners complained

NHTSA complaints by filing year. The peak shows at what age the problems show up most.

20057
200613
20074
20083
20091
20109
20113
20123
20135
20142
20152
20161
20201
20231

Comparison

By complaint count this model year ranks 5,078 of 36,656 model years in the NHTSA data (top 14% most complained about).

On average one model year of the E-350 has 27 complaints (44 years in the data). This year has 55, above average.

What to check before buying

Electrical system. Scan all modules, test the battery and alternator, inspect connectors near the impact zone.
Engine and cooling. Radiator and fan after a frontal hit, coolant level and condition, overheating.
Fuel system. Fuel smell, leaks, rough running, fuel-system codes.
Engine. Cold start, unusual noises, oil leaks and engine codes.

Other years of this model

Questions and answers

What are the most common problems with the 2005 Ford E-350?

Owner complaints to NHTSA most often mention: electrical system, engine and cooling, fuel system. Total complaints: 55. The most frequent symptoms in complaint texts: stalls while driving (24%), warning lights, check engine (24%), A/C or heater (15%).

How many service bulletins (TSB) were issued for the 2005 Ford E-350?

NHTSA lists 0 manufacturer service bulletins for this year. A bulletin tells dealers how to diagnose or fix a known issue; it is not a recall.

Should I buy a 2005 Ford E-350 from a US auction?

Owner complaints describe defects, not crash damage. Before bidding, check the components listed above and review the lot photos: VinWind builds a report of visible and hidden damage by VIN.

Other 2005 models

Read also

Sources: public NHTSA data (USA): service bulletins and owner complaints; YouTube: links to videos credited to their authors. Complaints are owner statements not verified by NHTSA, and describe defects rather than crash damage. Data updated 2026-11-05.