I have had a number of problems with my 23K mile 2005 F150 SuperCrew with the 5.4.
First I had a check engine light. 6x in the shop, dropped the fuel tank many times only to find a bad gas cap, or so they said.
Then the fuel gauge stuck below 1/4 after filling. I was told to put some cleaner in the tank. It did fix the problem for now anyway.
Now I get a "wrench" light on the dash and the truck goes into limp home mode and will not take fuel well. I found that shutting the engine off seems to reset things and it drives OK.
So I turn it in for warranty repair. They order a new throttle actuator and put it on the truck. Now the "wrench" light will not go out or reset at all. They still have the truck and another actuator has been ordered.
Seems that this one will only make it 8K miles or 8 month without a problem.
I have owned many Ford PUs without these types of problems.
Is anyone else having problems with this year truck besides me??

 

Not a single problem since I drove it off the lot(34,300 miles on odo).

 

Well I got it back, Just like the times before they could not fix it on the first attempt. This time they said the first actuator they got in was bad and had to order another.
23K miles in about 30 months and it's spent some 9 days in the shop testing and awaiting repairs.
Maybe it's time to get rid of this one.

 

I also have a 2005 5.4. I have also had a few problems. Check engine light, insufficient freon in AC, drivers side window dropped. I have taken it all in stride, but I sure expected better. If I had to do it again, I can't say I would do anything different.

 

Seems like they should of delayed this model a couple more months and did some better testing to work out the bugs!

Some people didn't have much of any issues, and others don't get out the shop........ Just lack of quality(hate to say it), but at least they are trying to fix most of the problems.

 

I also had an '05 with numerous issues:

Rear end clunking (3.73 LS) - in shop 3 times, never fixed...included a lubed slip yoke, new drive shaft, clutch packs.

4wd actuator (4 times) - even got stuck in the snow behind the shop with the service manager in the truck with me.

both hubs went at different times (think related to above)

driver's side window switch went.

I got fed up and traded in an '05 SCAB for an '07 SCrew with the 0%/60mos plan. It cost me $0 put of pocket and only $12/month more. The '05 was really testing my loyalty to Ford.

I have had zero problems with the new one. Only $4k on it - but no rear end clunk (same rear - 3.73 LS) and 4wd works fine.

 

I bought my 05 in June. Before I made my third payment, it was in the shop for the 3rd time. They finally figure out what was wrong. It was missing really bad, stalling out, and barely would run. Come to find out, both of the cats went out, so did 4 injectors (after replacing 3 the first 2 times in the shop) and plugs and wires. They had it for 3 weeks the last time, but since then I have had no trouble. I too am having trouble with the drivers side window switch. So far, knock on wood, that is all of the problems I have had.

 

I have an 05 with 76,000 miles on it and it has only been the shop for lof and brakes at 45,000. Rear brakes went about 2000 miles before front. I will need brakes and tires at 80,000. I have the KR supercrew 4x4 and have only added a Banks Exhaust. Sounds like a GT Mustang. Waiting for the 1/2 ton diesel to trade. Sorry fro your problems. Also, my company has an 04 spec the same with 120,000 miles .No problems other than 3 stuck plugs at 100,000. $750 later , plug change. I may trade before I need plugs if the dealer will not agree that seized plugs are his problem since Ford says change at 100,000.

 

If possible, take it to another dealer.

 

Ive had a few problems with mine but all have been worked out with the dealer. I had a tranny issue for awhile which turned out to be my fault. The dealer found 2 plugs with cracked porcelan that was causing a misfire. Other than that I had a few trim issues but I was being nit picky at the time. 05 Lariat 2wd