Fuel tank, filler or EVAP failure on the 2005 Ford F-150
1 fire 1 of the 6 reports for this failure mention a crash, a fire, an injury or a death. Those are the owner's words on the complaint form, not a verified finding, and one report can mention more than one.
Only 6 reports for this mode came with an odometer reading, which is too few for percentiles to mean anything. The page is here because someone linked to it; treat the figures as anecdotes, and see the full report for this year instead.
When fuel tank, filler or evap failure gets reported
There are 6 reports of fuel tank, filler or EVAP failure on the 2005 Ford F-150, 6 with a mileage attached. That is too few to place the failure on the odometer with any confidence.
A part like this is normally expected to survive 88,000 miles. It is the 39th most-reported problem on this model year.
The whole distribution
| 10th | 25th | Median | 75th | 90th |
|---|---|---|---|---|
| — | — | 130,000 miles | — | — |
Read the 10th percentile as “one report in ten arrived this early”. Exact figures are shown in this table because it is the table of record; everywhere else on the site they are rounded to the precision the sample can carry.
What a percentile can and cannot tell you here
These five numbers describe the readings owners gave, in order. The median is the middle one: half the reports arrived below it. The 10th and 90th are the edges of the bulk of the distribution, and the distance between them is the part worth reading. A tight spread — say 70,000 to 95,000 miles — points at something that wears out on a schedule, and the schedule is knowable. A wide one, 20,000 to 190,000, points at a fault that hits some cars and never troubles others, which means the mileage on the listing in front of you tells you very little about your odds.
What these figures are not is a survival curve. Every reading here comes from a car whose owner filed a complaint, so the sample contains only failures: it cannot say what share of the fleet made it past 150,000 miles untouched, because those owners had nothing to report. Nor is the mileage the moment of failure — it is the odometer reading as recalled at the time of filing, which may be weeks later and is sometimes rounded to the nearest ten thousand by the person typing it.
Percentiles are shown at all only once 8 readings exist for the vehicle and mode. Below that the middle of a handful of numbers is noise wearing a decimal point, so the figures are withheld rather than dressed up.
What happens, and what it costs
Of these reports, 1 a fire is mentioned. Owners write their own complaints and the agency does not verify them, so read this as what the reports say happened rather than as a confirmed count.
Putting it right typically runs $250–$1,800 at an independent US shop. That range is an editorial estimate held in this site's failure-mode catalogue, not a figure from NHTSA, and it is a repair cost rather than a diagnosis cost.
The same failure on other years
The same failure is reported on 22 model years of this car. It shows up earliest on the 2018, at a median of 5,000 miles, and latest on the 2024 at 145,000 miles.
By volume the 1997 carries the most reports, with 206; the 2005 has 6. A mode that appears across most years of a model is usually a design choice rather than a bad batch.
If one year stands out to the left, that is the year to avoid; if the whole line sits at a similar mileage, this is wear rather than a defect in one production run.
Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens
What owners wrote
Verbatim from NHTSA complaint narratives, trimmed for length. The mileage is the one the owner gave.
Tl*the contact owns a 2005 ford f-150. While driving approximately 35 MPH on normal road conditions, the bed and cab compartments of the vehicle burst into flames. The contact was notified by another motorist. He immediately turned off the engine and exited the vehicle. He noticed fuel leaking from the vehicle onto the roadway, which also caught fire. The vehicle became engulfed in flames and was destroyed. There were no warnings prior to the fire. The fire and police departments were called to the scene and a report was filed. The fire department stated that the fire originated on the top surface of the fuel tank. There were no personal injuries or property damage. The vehicle was towed to a collision center. The manufacturer was notified of the malfunction and the insurance company has not determined the cause of the failure. The failure and current mileages were 47,000.
Check engine light came on with code p0442 indicating evap emission control system small leak. Mechanic performed smoke test and found severed fuel line on top of the fuel tank. It appears the line was faulty in that it was relatively protected on top of the fuel tank. Also, this line is directly adjacent to the muffler which is a potential fire hazard. *tr
Truck would idle extremely bad, when you cut it off it wouldn't start. This started happening on friday, december 31, 2010. I took the truck to firestone and they run a diagnostic test which at the time did not show the throttle body problem because the "check engine" light was not on at the time. However, firestone replaced the fuel filter, did a tune up and replaced the battery and removed the gas tank to clean it but this still did not resolve the problem and this cost me $369. The truck was then taken to a ford dealership and on the way there the "check engine" light did come on. The dealership advised us after the diagnostic test that we needed a throttle body and electronic EGR valve which will cost $1330.00. *tr
Also reported on the 2005 Ford F-150
Other visibility problem
Window regulator or power window failure
Other engine problem
Other powertrain problem
Misfire or rough idle
Other electrical problem
How far this goes
This page is kept out of search results because 6 reports is not enough to publish percentiles from. It stays reachable because somebody looking at this exact car would rather see the reports than be told there are none.
Complaints are voluntary, so 6 is a floor and not a count of affected cars. Mileages are typed in by owners and cluster on round numbers. And the mode itself is assigned by software reading the complaint text, which is reliable in bulk and fallible one report at a time.
Questions this page answers
At what mileage does fuel tank, filler or evap failure happen on the 2005 Ford F-150?
Across 6 owner reports that included an odometer reading, half were filed by 130,000 miles. A quarter were filed before — and a quarter after —. These are the mileages owners reported when they complained, not a prediction for any individual car.
How common is fuel tank, filler or evap failure on the 2005 Ford F-150?
6 reports have been filed with NHTSA, about 0.0 per 1,000 vehicles. Complaints are voluntary, so this is a floor rather than a count of affected cars.
What this is and is not. These are the mileages at which owners chose to complain to a federal agency, which is not the same as the mileage at which the part fails on every car. It skews toward failures that happened outside warranty, cost real money, or frightened someone. It is still the only public dataset that carries failure mileage at all, and the shape of a few hundred readings is informative even when a single one is not. Methodology · JSON · this failure on other cars
Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt Published by AtWhatMileage How every figure is computed