2005 Ford F-150 body problems

Filed Nov 1, 2025 · Body, Transmission · IN

customer states that the frame of the vehicle has been compromised by corrosion. the vehicle only has 163,844 miles on it and it has major holes in the frame. The chassis could break in half prohibiting the use of this vehicle on the roadway due to the safety of occupants. I advised the customer of this of which they bought a frame repair kit (Pre-cut over frame c-channel steel) to weld onto the frame to support a longer lifespan. The truck is now safe for the roadway.

Filed Jul 19, 2025 · Body · OK

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.

Filed Feb 11, 2024 · Body · MO

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

Filed Jan 7, 2024 · Body, Steering · IL

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.

Filed Aug 3, 2023 · Body · 170,000 miles · RI

The contact owns a 2005 Ford F-150. The contact stated that when he had the vehicle serviced that the independent mechanic informed him that the front and rear frame of the vehicle was rusted and he should not be driving the vehicle. The manufacturer was made aware of the failure but provided no assistance but did inform the contact to contact the federal safety agency. The failure mileage was approximately 170,000.

Filed May 9, 2023 · Body · IN

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

Filed Apr 27, 2023 · Body · 75,000 miles · IL

The contact owns a 2005 Ford F-150. The contact stated that the bed of the truck was lower than usual. The contact looked underneath the vehicle and became aware of rust underneath the vehicle. The vehicle was taken to an independent mechanic and the mechanic stated that the vehicle was rusted and that the sub frame was cracking and referred the contact to the dealer for assistance. The dealer was contacted, and the dealer stated that the vehicle needed to be inspected. The manufacturer was contacted, and the manufacturer stated that the vehicle was not under recall and referred the contact to the federal safety agency Hotline for assistance. The approximate failure mileage was 75,000.

Filed Apr 14, 2023 · Body · 114,000 miles · OH

The contact owns a 2005 Ford F-150. The contact stated that the vehicle was taken to an independent mechanic, who informed the contact that the subframe was severely rusted. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure and referred the contact to file a complaint with the federal safety agency Hotline. The failure mileage was approximately 114,000.

Filed Jan 25, 2023 · Body · MN

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.

Filed Sep 22, 2022 · Body · PA

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.