2005 FORD MUSTANG — Problems, Recalls & Safety Data

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.

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.

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.

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.

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.