2005 Ford F-150 Body & structure Problems

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.

NHTSA ID

11696954

Incident

Nov 1, 2025

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.

NHTSA ID

11674785

Incident

Jul 7, 2025

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

NHTSA ID

11571312

Incident

Dec 11, 2021

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.

NHTSA ID

11564033

Incident

Dec 29, 2023

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 NHTSA. The failure mileage was approximately 170,000.

NHTSA ID

11536319

Incident

Aug 1, 2023

Mileage

170,000 mi

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

NHTSA ID

11521101

Incident

Nov 10, 2022

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 NHTSA Hotline for assistance. The approximate failure mileage was 75,000.

NHTSA ID

11519249

Incident

Apr 13, 2023

Mileage

75,000 mi

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 NHTSA Hotline. The failure mileage was approximately 114,000.

NHTSA ID

11517030

Incident

Apr 13, 2023

Mileage

114,000 mi

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.

NHTSA ID

11503724

Incident

Jan 25, 2019

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.

NHTSA ID

11485787

Incident

Aug 31, 2022

The frame of the vehicle is rusted through in multiple spots. When I picked the vehicle up on the lift the weight of the vehicle crushed the bottom side of the frame upward 1/2" upon inspection below the front doors where the frame is welded together it is also rusted through. While looking up recalls I found images and videos of other same generation F-150's that have the same problem. 1 video the entire bottom side of the frame from the engine to the front leaf spring mounts was rusted through. U-haul is aware of the issue and doesn't allow certain Ford vehicles to tow their trailers due to this issue. It's only a matter of time before the frames start breaking like the Toyota pickups and accidents start to come in.

NHTSA ID

11453273

Incident

Feb 20, 2022

This and many other trucks of this generation have major frame rot issues due to the box frame. The rest of my truck looks excellent but the frame is so bad its most likely not repairable. I am not the only one with this major safety issue. Its only a 16 year old truck. Thankfully I have not towed or put a large load in the bed or else it could split in half. I wash my car seasonally and pressure wash off rust every spring. Yet the frame has rotted so badly they could not put it on a lift to do the alignment. I love this truck and I'm a big fan of the f150 line as a whole. Ford should take responsibility as Toyota has and fix their customers frames from this generation. I love ford but its always interesting walking through a parking lot and seeing every 04-08 f150 with major frame rot. Without fail every single one has that issue. Seems to me like they didn't properly galvanize and protect the steel. I am now needing to do a bed off frame restoration since no shop will take it on. This truck that should be going for $5k with this insane used car market. (August 3rd 2020) yet it is max $200 in scrap. Bad / cheap engineering should not be the owners responsibility. Yet that is what it has come to. It was most likely an honest unforseen mistake on their part. Overengineering the rigidity but ignoring the long term effects. Short term strength for log term pain as is commonly said with these trucks. I'm sure in a few years time these will just start breaking in half over bumps on the freeway. I beg and encourage ford to fix this before people die. I doubt ford wants another pr fiasco like the pinto. Hopefully they will do a cost analysis and realize that a recall is a much better option. Seem like 250-500k a pop for settlements for the most popular truck of all time is much much more than 5k per affected vehicle. Not including the long term dip in sales. So unless they want the other brands to win the truck war they gotta fix it. Tldr: a recall is cheaper than death.

NHTSA ID

11427546

Incident

Aug 3, 2021

FRAME RUSTING TERRIBLY AND FRAME CRACKING NEAR DRIVERS SIDE FORWARD LEAF SPRING MOUNT. TRUCK HAS ONLY 128,000 MILES. DO NOT HAUL OR TOW ANY WHERE NEAR THE TRUCKS CAPACITY. NORMAL DRIVING AND MINOR OFF ROAD USE.

NHTSA ID

11413821

Incident

Apr 15, 2021

Mileage

127,000 mi

PURCHASED VEHICLE FEB 2021 FROM PRIVATE OWNER. TOOK VEHICLE IN FOR SERVICING. SERVICE DEPARTMENT INFORMED ME THAT THE OIL CHANGE COULD NOT BE COMPLETED, BECAUSE THEY WERE AFRAID TO PLACE THE VEHICLE ON THE LIFT DUE TO THE FACT THAT IT MIGHT SPLIT DUE TO THE FRAME BEING RUSTED COMPLETELY THROUGH. FURTHER, I WAS TOLD THAT THE VEHICLE WAS UNSAFE TO DRIVE DUE TO THE EXTENSIVE CORROSION OF THE FRAME ON BOTH THE PASSENGER AND DRIVER SIDE. I WAS INFORMED THAT AT ANY TIME, IF I HIT A BUMP OR WAS HIT FROM BEHIND, THE VEHICLE WOULD FOLD IN HALF. COMPLAINT ID #: ODI 11413329

NHTSA ID

11413622

Incident

Apr 15, 2021

Mileage

75,646 mi

TL* THE CONTACT OWNS A 2005 FORD F-150. THE CONTACT STATED THAT HE LEARNED THAT HIS VEHICLE WAS SEVERELY RUSTED ON THE PASSENGER'S AND DRIVER'S SIDE OF THE VEHICLE. THE VEHICLE WAS RUSTED FROM THE MIDDLE OF THE VEHICLE TO THE REAR OF THE VEHICLE. THE CONTACT HAD TAKEN THE VEHICLE TO A CERTIFIED MECHANIC AS WELL AS TWO BODY SHOPS WHO STATED THAT THE ENTIRE SUBFRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 76,000.

NHTSA ID

11413329

Incident

Apr 21, 2021

Mileage

76,000 mi

COMPLETE FRAME UNDER TRUNK IS RUSTED TO WHERE THE FRAME IS GETTING READY TO BREAK IN HALF I HAVE LOOKED AT SEVERAL OTHER OF THE SAME MAKE AND MODEL AND THEY HAVE THE SAME SIMILAR PROBLEMS SO I'M NOT AS BAD AS OTHERS BUT 90% OF THEM ARE NOT SAFE TO DRIVE I LIVE IN THE AREA THERE'S NOT A LOT OF SALT NORE SAND IF THIS WAS A PROBLEM WITH JUST MY VEHICLE I WOULD UNDERSTAND BUT SINCE IT IS A PROBLEM WITH A LOT OF THESE TRUCKS SOMETHING NEEDS TO BE DONE BUY FORD MANUFACTURES.

NHTSA ID

11407009

Incident

Apr 7, 2021

WENT TO HAVE TRUCK LINED UP AND WAS TOLD IT HAD RUSTED THE FRAME ALMOST INTO IN THE REAR. IN MORE THAN ONE PLACE.

NHTSA ID

11385401

Incident

Dec 15, 2020

Mileage

170,000 mi

HAD VEHICLE TOWED TO A REPAIR GARAGE TO HAVE STARTER REPLACED.ACCORDING TO REPAIR TECH.WHILE LIFTING TRUCK A LOT OF CRACKING SOUND S INSPECTION OF FRAME REVILED EXCESSIVE RUSTING AND CRACKS .THEY CALLED AND TOLD ME TRUCK WAS UN SAFE TO USE.HAVE BILLS WITH STATEMENTS MADE BY REPAIR SHOP.

NHTSA ID

11364380

Incident

Aug 15, 2020

Mileage

1,150,000 mi

TL* THE CONTACT OWNS A 2005 FORD F-150. THE CONTACT STATED THAT WHILE THE VEHICLE WAS AT THE LOCAL DEALER MEL ERVIN FORD LOCATED AT 15455 OAKLEY RD, CHESANING, MI 48616, IT WAS DISCOVERED THAT THE SUB FRAME OF THE VEHICLE EXPERIENCED RUSTING AND CORROSION UNDER THE CABIN SECTION OF THE VEHICLE. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 75,000.

NHTSA ID

11360971

Incident

Sep 3, 2020

Mileage

75,000 mi

TL* THE CONTACT OWNS A 2005 FORD F-150. AFTER REPLACING THE TIRES ON THE VEHICLE, THE CONTACT HEARD A CRACKING NOISE WHEN THE VEHICLE WAS PLACED ON A LIFT. THE INDEPENDENT MECHANIC CONFIRMED THE FRAME WAS RUSTED THROUGH TO THE POINT THAT IT WAS UNSAFE TO PLACE ON THE LIFT. THE VEHICLE WAS TAKEN BACK TO FREDERICK MOTOR COMPANY (1 WAVERLEY DR, FREDERICK, MD 21702, (800) 734-9118). THE CONTACT WAS INFORMED THAT THEY COULD NOT ASSIST SINCE THE VEHICLE WAS NOT INCLUDED IN A RECALL. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 57,000.*BF*JB

NHTSA ID

11289564

Incident

Dec 7, 2019

Mileage

57,000 mi

TL* THE CONTACT OWNS A 2005 FORD F-150. THE CONTACT STATED THAT THE VEHICLE'S FRAME WAS CORRODED, WHICH CAUSED THE TRANSMISSION LINE TO BECOME DEFECTIVE. THE CONTACT TOOK THE VEHICLE TO AN INDEPENDENT MECHANIC WHERE THE TRANSMISSION LINE WAS REPLACED. THE CONTACT WAS INFORMED BY THE MECHANIC THAT, DUE TO THE CORROSION, OTHER PARTS OF THE VEHICLE COULD BECOME DEFECTIVE. THE MANUFACTURER AND DEALER WERE NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 95,000.

NHTSA ID

11287097

Incident

Dec 3, 2019

Mileage

95,000 mi

THE ENTIRE FRAME IS RUSTING OUT. EVERYWHERE I LOOK THERES RUST. ALL OF THE CROSS FRAME FROM FRONT TO BACK DOWN SIDES AND ACROSS BOTTOM OF BED AND WHERE FLOOR BOARDS ATTACH LIKE WAS EXPENSIVE TRUCK FORD HAS TO KNOW

NHTSA ID

11281103

Incident

Nov 19, 2019

Mileage

76,070 mi

TL* THE CONTACT OWNS A 2005 FORD F-150. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC TO HAVE FRONT AND REAR SHOCKS INSTALLED. THE MECHANIC INFORMED THE CONTACT THAT DUE TO THE SEVERE RUST DAMAGE TO THE SUBFRAME, IT WAS NOT RECOMMENDED TO HAVE THE SHOCKS REPLACED. THE CONTACT WAS INFORMED THAT THE VEHICLE WOULD NOT PASS STATE INSPECTION WITHIN THE NEXT FEW MONTHS. THE VEHICLE WAS NOT REPAIRED. THE DEALER AND MANUFACTURER WERE NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 180,000. *LN*JB

NHTSA ID

11280334

Incident

Nov 14, 2019

Mileage

180,000 mi

EXTENSIVE MAIN FRAME RAIL RUST RENDING TRUCK UNSAFE TO DRIVE NOW. STARTED AROUND 2010.

NHTSA ID

11252141

Incident

Jul 15, 2017

Mileage

60,000 mi

BOUGHT TRUCK LEAST WEEK TOOK IN FOR A OIL CHANGE AND WAS TOLD THAT THE FRONT HALF SHAFT IS ROTTEN TO THE POINT IT'S PITTING. THE STEERING SHAFT IS RUSTED OUT AND THE MAJORITY OF THE FRAME IS RUSTED OUT NEAR WHERE ALL THE IMPORTANT PARTS OF THE VEHICLE ARE HELD IN PLACE. AS I DO RESEARCH ON THIS PROBLEM I'M FINDING IT IS A COMMON PROBLEM. THE TRUCK ONLY HAS 61000 MILES ON IT AND IT SHOULDN'T HAVE THIS MUCH WEAR ON THE BODY OF THE TRUCK. FORD REALLY NEEDS TO LOOK INTO A RECALL BECAUSE THERE ARE THOUSANDS OF TRUCKS WITH THIS SAME ISSUE. I HAVE NEVER OWNED A FORD AND NEVER WILL AGAIN. THE CAR IS BASICALLY WORTHLESS AND IT'S A MATTER OF TIME WHEN IT RUSTS ALL THE WAY THRU. STATIONARY ISSUE. I DON'T HAVE ANY PHOTOS AS OF RIGHT NOW. I WILL BE TAKING MORE THE OIL SHOP HAS PICTURES THAT HE SHOWED ME.

NHTSA ID

11231768

Incident

Jul 14, 2019

Mileage

61,000 mi