Other fuel system problem on the 2005 Ford F-350 SD
1 fire 1 of the 10 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.
When other fuel system problem gets reported
Owners of the 2005 Ford F-350 SD report other fuel system problem at a median of 95,000 miles. A quarter of the reports come in before 65,000 miles and a quarter after 115,000 miles, from 10 reports that carried an odometer reading.
A part like this is normally expected to survive 90,000 miles. It is the 7th most-reported problem on this model year.
The mileage distribution
The reported range runs from 15,000 miles at the tenth percentile to 140,000 miles at the ninetieth, a spread of 126,468 miles across the middle 80% of reports.
When the reports scatter this far, the mileage is telling you about how these cars were driven more than about the part itself.
20% of the dated reports were filed under 36,000 miles.
The whole distribution
| 10th | 25th | Median | 75th | 90th |
|---|---|---|---|---|
| 13,970 miles | 67,078 miles | 93,000 miles | 116,427 miles | 140,438 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 $300–$2,200 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 17 model years of this car. It shows up earliest on the 2002, at a median of 25,000 miles, and latest on the 2018 at 160,000 miles.
By volume the 2015 carries the most reports, with 18; the 2005 has 10. 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.
Dt: consumer reports: he bought a 2005 f-350 and he got a recall letter in the mail. He called the dealer to schedule an appt. To get it fixed and they refused to schedule him an appt. They refused to schedule an appt. With him. The recall letter was concerning the fuel jumper line. *jb
The failure of diesel fuel injectors in the '05 ford f-350 super duty trucks with the power stroke 6.0l diesel engine. Vehicle had approx. 14,800 miles on it at the time of the incident. Did not lead to an accident, I feel that it could in another case. There were no warnings that this was going to happen and occurred suddenly without warning. I was driving into town(about 17 miles). On the interstate highway traveling at approximately 75 MPH. My vehicle lost most of it's power and began to jerk and sputter as I pulled to the side of the road. Shut vehicle off, did a basic check of the vehicles components and then restarted . Started and ran fine. I began to merge into traffic only to loose significant power and was forced to return to the side of the road. I was seriously slowing the oncoming traffic. I began to limp my truck to the nearest exit ramp. Exited the interstate, my truck died and left me stranded, not able to restart. Vehicle towed to the dealership for repair. At the repair shop, the #1 cylinder injector was determined to have failed and was replaced with a new or rebuilt part. (this is not specified by ford.) I…
Vehicle had just returned home after being driven a considerable distance. Vehicle shut off for a few minutes when fire started under the hood and moved into cab. Insurance company hired a fire origin and cause analyst and it was determined that fire was caused when fuel leaked from the banjo fitting on the fuel filter onto the hot surface of the engine. The banjo fitting on the lower portion of the fuel filter was covered with a heavy layer of fuel varnish. The bolt in the banjo fitting was checked and found to be extremely loose. This occurred on 6.0l diesel engine. There looks to have been similar problem on gasoline engines which had a recall date of 6/7/05 and NHTSA id number of 05v266000. Would like to know if ford has seen problem on diesel engines?*jb
Also reported on the 2005 Ford F-350 SD
Other suspension problem
Other steering problem
Other engine problem
Other electrical problem
Other wheel or tire problem
Other powertrain problem
How far this goes
Complaints are voluntary, so 10 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 other fuel system problem happen on the 2005 Ford F-350 SD?
Across 10 owner reports that included an odometer reading, half were filed by 95,000 miles. A quarter were filed before 65,000 miles and a quarter after 115,000 miles. These are the mileages owners reported when they complained, not a prediction for any individual car.
How common is other fuel system problem on the 2005 Ford F-350 SD?
10 reports have been filed with NHTSA, about 0.5 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