2005 Ford Mustang

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016 four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016 four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The investigation now includes all manufacturers and vehicles known to be affected at this time.ODI's investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

On November 18, 2010, NHTSA's Recall Management Division (RMD) opened an audit query (AQ10-001) to investigate recall remedy completion by rental car companies on safety recall campaigns.It was expected to provide the agency an indication of how completely and how quickly rental car fleets perform necessary recall-related remedies on the vehicles owned and then rented/leased for use on the roadways.RMD queried three (3) major motor vehicle manufacturers (Ford, Chrysler, and General Motors) and requested data regarding completion figures for fifteen (15) discreet safety recalls.Analysis of this data demonstrated that rental car recalls completion was neither complete nor consistent.The rental car companies representing the largest market share in the industry were then queried as to their respective policies for the rental, lease, and sale of vehicles with open recalls.The data and responses from the manufacturers and the rental car companies can be found in the document repository by accessing the ?Associated Documents link above.In December 2015, Congress enacted the Fixing America's Surface Transportation (FAST) Act.One section of the Act prohibits rental car companies from renting, leasing, or selling motor vehicles subject to open safety recalls.With the passage of the FAST Act and its prohibition, there is no continuing need for the agency to investigate rental car recall completions.Accordingly, this investigation is closed.The agency reserves the right to open any future investigations, including audits of individual recalls, or groups of recalls, or rental car companies, to examine more closely safety recalls performance and completion issues in this area.

The contact owns a 2005 Ford Mustang. The contact stated that while her husband was attempting to fuel the vehicle, the fuel tank was unable to be fully fueled. The contact stated that either the nozzle would shut off prematurely or gasoline would be prevented from flowing into the fuel tank. There was no warning light illuminated. The contact stated that the failure was intermittent, but by late 2024, the fuel tank could no longer be filled, and the vehicle was placed in storage. The vehicle was taken to a local dealer prior to being placed in storage, and the contact was informed that the fuel tank needed to be replaced. The contact was made aware of Technical Service Bulletin Number: 05-15012; however, the vehicle was not covered under warranty. The vehicle was not repaired. The manufacturer was informed of the failure and referred the contact to the NHTSA Hotline. The failure mileage was approximately 32,000.

NHTSA ID

11678583

Incident

Oct 7, 2024

Mileage

32,000 mi

The contact owns a 2005 Ford Mustang. The contact stated that the check engine warning light was illuminated. While driving at approximately 25-35 MPH for approximately two miles, the engine started overheating. The oil pan gasket was leaking. The contact stated that the failure was related to NHTSA Campaign Number: 16V779000 (Engine and Engine Cooling). There were several hoses that were split. The vehicle was taken to an independent mechanic who determined that the radiator and engine were cracked, and the pistons were loose. There was air in the oil. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 123,000.

NHTSA ID

11650264

Incident

Dec 26, 2024

Mileage

123,000 mi

The contact owns a 2005 Ford Mustang. The contact stated that during inclement weather, water was entering the cabin of the vehicle through the passenger’s side glove box. The contact stated that due to the failure, mold had developed throughout the vehicle on the carpet, doors, and interior seats. The contact's husband also discovered that water had entered the computer module after inspecting the vehicle and the module was removed. The contact stated that the vehicle was inoperable after several repairs and several battery replacements. The vehicle was not repaired. The contact called the dealer and was referred to the manufacturer for assistance. The manufacturer was notified of the failure but offered no assistance. The failure mileage was 87,000.

NHTSA ID

11643908

Incident

Jun 1, 2022

Mileage

87,000 mi

I have experienced two engine failures in my 2005 Ford Mustang due to timing chain issues, specifically the failure of the timing chain cassette, guides, and tensioners in the 4.0L SOHC V6 engine. The first failure happened suddenly with no warning, resulting in severe bottom-end damage, including rod knock. The timing chain cassette ends tend to snap off, sending debris through the engine and damaging lifters, camshafts, and other critical components. The second failure was preceded by an audible “death rattle,” a known symptom of timing chain guide and tensioner failure. Despite this, my vehicle never displayed a check engine light or oil pressure warning before either failure. Unlike later Mustangs with an oil pressure gauge, mine only has a warning light, which never activated.This issue poses a major safety risk, especially at highway speeds. My first engine failure occurred with no prior symptoms, which could have led to an accident had I been merging or overtaking. A failing timing chain can cause misfires, loss of power, or sudden engine shutdown, endangering the driver and others on the road. Independent mechanics have confirmed this issue, and Ford service centers recognize it as a common problem with the 4.0L SOHC V6 engine. Ford has quoted $3,000–$4,000 for timing chain service, making repairs nearly as expensive as engine replacement. These engines rely on multiple chains and hydraulic tensioners that wear out over time, causing slack in the timing chain, jumped timing, and catastrophic damage, typically after 100,000 miles. Despite this, there are no clear warning systems to alert drivers before failure occurs. While timing chains are considered serviceable components, the high failure rate of the timing chain guides and tensioners in these engines, combined with excessive repair costs, indicates a design flaw. I have spent around $4,500 addressing this issue, yet the risk of recurrence remains.

NHTSA ID

11643850

Incident

Feb 19, 2025

Ford did issue a recall for several issues for my car, including but not limited to, problems when filling gas tank with evaporative purge system as well as cavitation of the fuel pump in high heat conditions, the doors not closing all the way or handles remaining open( not flush with rest of door) when door is shut, driver's side door trim/bezel around power window switch making buzzing sounds when stereo is in use, as well as ticking sounds coming from motor during operation and various creaks and sounds from front suspension when cornering and going over uneven terrain, and the transmission, the 5r55s, has the known hard shift into gear caused by bad servo. I have reached out to the dealers in my area regarding these issues and even though my car is the correct model and year for the service recall bulletins and has the exact issues described there in, I am told that the vin on my car is not covered even though it is clearly suffering from equipment that exhibits all the same problems listed in the recall. I feel the responsibility to perform and pay for these repairs should fall on the manufacturer, not i, the customer.

NHTSA ID

11638493

Incident

Oct 16, 2024

The contact owns a 2005 Ford Mustang. The contact stated while driving 65 MPH on a rainy night, the headlights started flickering. The contact stated that upon exiting the freeway, while driving 30 MPH, the headlights completely turned off and the hazard lights were inoperable. The contact drove to the nearest gas station and turned off the vehicle. The contact stated that upon attempting to restart the vehicle, the vehicle failed to restart. The vehicle was towed to the residence. The dealer and the manufacturer were not notified of the failure. The vehicle was not diagnosed or repaired. The failure mileage was approximately 170,000.

NHTSA ID

11626876

Incident

Nov 8, 2024

Mileage

170,000 mi

I purchased this car from Trent Family Auto on May 2, 2024. On September 11, 2024 the engine failed. While working on replacing the engine I found an open recall. This is safety related and was never mentioned to me by the dealership. So aside from selling me a bad "as is" they sold me an unsafe vehicle. A vehicle my family has ridden in several times since the purchase. In regard to the recall when I reached out to them about the engine replacement cost they stated recalls can only be taken care of by manufacturing dealerships. Shouldn't they have some ownership to inform customer buying an unsafe vehicle there is an open recall? Thank your for checking into this matter.

NHTSA ID

11619958

Incident

Oct 7, 2024

Took the 2005 Mustang GT in several years ago to have one airbag replaced. Dealer (Autonation Torrance, California) stated parts were not available for the other side. One of the airbags has never been replaced. I now read there is a "Do Not Drive" recall for vehicles of this year and model in "Zone A".

NHTSA ID

11608307

Incident

Aug 13, 2024

Certain 2005-2014 Mustang, 2005-2006 GT, 2004-2011 Ranger, 2006-2012 Fusion and MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge & MKX Vehicles Driver & Passenger Airbag Module Quality Control Inspection REASON FOR THIS SUPPLEMENT • Updated Ranger Technical Information to include images of a pass and fail airbag inflator inspection for 2007-2011 model years.

For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. Most modules on these affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are followed when diagnosing the condition prior to all module replacements and only order modules using the correct VIN.

Certain 2005-2014 Mustang, 2005-2006 GT, 2004-2011 Ranger, 2006-2012 Fusion & MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge & MKX Vehicles Driver & Passenger Airbag Module Quality Control Inspection: Ford Motor Company has determined that some vehicles claimed by dealers as repaired under Takata Airbag Safety Recalls 15S21, 17S42, 18S02, 19S01, and 21S12 may not have received the claimed repairs. The propellant in certain Takata airbag inflators can experience an alteration over time with exposure to certain climate conditions. A combination of time, high temperature fluctuations, and humidity contribute to the degradation of the propellant in the inflators. This degradation can cause the propellant to burn too quickly, creating high pressure inside the inflator, and in extreme cases causing the inflator to rupture in the event of a crash necessitating airbag deployment. A ruptured inflator can send inflator parts toward vehicle occupants resulting in serious injury or death. Additional information regarding Takata recalls can be found at www.nhtsa.gov and www.safercar.gov.

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended.

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition