2005–2007 Ford F-250 / F-350 Super Duty common problems and fixes

These trucks came with the 6.0L Power Stroke diesel, the 5.4L V8 gas or the 6.8L V10 gas.

We counted 1,696 owner complaints filed with NHTSA for 2005–2007 F-250s and F-350s (retrieved October 5, 2026; each complaint counted once): 956 from 6.0L diesels, 386 from 5.4L V8s and 64 from 6.8L V10s, identified by VIN; the rest (290) couldn't be matched to an engine. We left out 15 whose VIN belongs to another vehicle (e.g. an F-150 or an E-Series van). Complaint counts show what owners report most often, not how many trucks have a problem.

At a glance

• Front-end shake ("death wobble") is reported on every engine: about 3 in 10 complaints (about 510 of 1,696) mention a wobble or shimmy or shaking after a bump, and nearly half of 5.4L gas truck complaints (175 of 386).
• The 6.0L diesel has a well-known chain of failures (oil cooler, EGR cooler, head gaskets) plus FICM and injector problems. Many have been fixed by now; records are everything.
• The 5.4L and 6.8L gas engines are known for spark plugs that break during removal and for cam phaser noise.
• Rust is a major concern at this age.

Front-end shake ("death wobble")

Owners describe a violent shake of the front end and steering wheel after hitting a bump at speed. NHTSA files about 850 of these trucks' complaints under steering or suspension. Owners on forums most often report lasting fixes from replacing worn parts, especially the track bar, ball joints and tie rods, and not just the steering stabilizer.

When buying: have a helper rock the steering wheel with the engine running while you watch the track bar and tie rod ends for movement. Hit some bumps at highway speed on the test drive.

6.0L diesel

The 6.0L's reputation comes from a common failure chain described by many repair shops: the oil cooler clogs, which starves and cracks the EGR cooler, which then helps blow the head gaskets. Other frequently reported problems:

• Stalling, about 1 in 4 of 6.0L complaints (about 230 of 956 mention stalling, dying, cutting out or shutting off); certain 2005 trucks were recalled for one cause of it (see recalls below)
• The FICM (fuel injection control module), which causes hard starts and misfires when it weakens
• Injectors and turbo vane sticking

Many 6.0L trucks have been "bulletproofed" by now: head studs and upgraded oil and EGR coolers. That's a big plus if there are receipts. One that hasn't been done should be priced with that work in mind.

When buying: look for coolant loss with no visible leak, white smoke, or coolant being pushed out of the coolant bottle. Ask a diesel shop to compare engine oil and coolant temperatures on a scan tool. A large gap is a classic sign of a clogged oil cooler.

5.4L and 6.8L gas

These are the 3-valve versions of Ford's gas engines. Repair sources commonly report that their two-piece spark plugs break off in the head during replacement, which makes a routine tune-up much more expensive. Cam phaser and timing chain noise is also frequently discussed, especially with missed oil changes.

When buying: ask when the spark plugs were last changed and how it went. Listen for a ticking or diesel-like rattle at idle.

Recalls to check on these years

Ford has issued only a few recalls for these trucks, and none for 2006–2007 trucks as they were built:

• 2005 6.0L diesel may stall without warning and may not restart on certain trucks; dealers repair the FICM wiring harness and the ICP sensor connector (recall 05V270000, which also covers 2004)
• 2005 5.4L and 6.8L gas fuel line may separate at a connection on certain trucks, leaking fuel, with a fire risk; dealers add a retaining clip (recall 05V266000)
• Replacement turn signal switches: a dealer may have fitted one of the faulty multi-function switches sold as a service part for 2002–2007 trucks, which can stop the turn signals or other lights working (recall 11V352000)

NHTSA's list for these years also includes recalls for aftermarket parts, such as lift blocks, steering stabilizers, wheels and towing adapters, and for some original tires on 2006 trucks. These matter only if the truck has those parts.

Rust

Check the cab corners, rocker panels, wheel arches, radiator support and brake lines, and look along the whole frame for scaling or holes.

Before you buy

• Check open recalls at nhtsa.gov/recalls with the VIN.
• For a 6.0L, get a pre-purchase inspection from a shop that knows the 6.0 and ask what's been upgraded.
• Bring our used truck inspection checklist.