2005 Ford F-150 structure problems
77 owner complaints filed with NHTSA name the structure on the 2005 Ford F-150 — 7% of all complaints for this model year.
What owners report
“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…”
filed 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…”
filed Jul 19, 2025
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Related service bulletins
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…
SSM 51536 · Service Bulletin/Repair Instructions · issued Apr 4, 2023This 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…
TSB 20-2233 · Service Bulletin/Repair Instructions · issued Jul 13, 2020Some 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…
TSB 19-2026 · Service Bulletin/Repair Instructions · issued Feb 7, 2019Some 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…
TSB 19-2026 · Service Bulletin/Repair Instructions · issued Feb 7, 2019
Structure problems in other F-150 years
| Year | Reports | Share |
|---|---|---|
| 2025 F-150 | 3 | 3% |
| 2024 F-150 | 2 | 1% |
| 2023 F-150 | 21 | 5% |
| 2022 F-150 | 14 | 2% |
| 2021 F-150 | 35 | 4% |
| 2020 F-150 | 22 | 3% |
| 2019 F-150 | 31 | 2% |
| 2018 F-150 | 191 | 8% |
| 2017 F-150 | 109 | 8% |
| 2016 F-150 | 199 | 10% |
| 2015 F-150 | 147 | 9% |
| 2014 F-150 | 31 | 2% |
Other reported problem areas on the 2005 Ford F-150
Counts are unique NHTSA complaints naming this component group. Complaints are unverified owner reports; mileage is computed only from complaints that included a usable odometer reading.