2005 Ford Mustang Problems: 6 Issues Every Owner Should Know

2005 model year · 0+ owner reports · Updated April 2026

According to Au7o's analysis of 0+ owner reports, the 2005 Ford Mustang has 6 documented known issues, with 3 rated critical. The most serious are Fuel Tank Cracking and Fuel Vapor/Fuel Leak at Tank Seam or EVAP Area ($900-$1,800 repair), Takata Driver Airbag Inflator Rupture Risk ($0-$0 repair) and S197 Passenger Seat Occupant Classification Sensor Fault Causing Airbag Warning and Disabled Passenger Airbag ($700-$1,800 repair). Across all issues, repair costs range from $0 to $1,800. DIY maintenance guides at au7o.io.

All 6 Known Issues

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When Issues Typically Appear

Takata Driver Airbag Inflator Rupture Risk

0K-200K

2005-2010 Smart Junction Box Water Intrusion Causing Wiper, Lighting, and Electrical Malfunctions

30K-150K

Fuel Tank Cracking and Fuel Vapor/Fuel Leak at Tank Seam or EVAP Area

40K-120K

S197 Passenger Seat Occupant Classification Sensor Fault Causing Airbag Warning and Disabled Passenger Airbag

40K-120K

Front Strut Mount and Sway Bar End Link Clunking on S197 Suspension

50K-120K

4.0L Cologne V6 Thermostat Housing Cracking and Coolant Leaks

60K-140K

050K100K150K200K mi

On the 2005-2014 Ford Mustang, many 2005-2014 Mustangs were included in the Takata airbag inflator recalls. The driver airbag inflator can degrade over time, especially in hot and humid climates, and may rupture during deployment, sending metal fragments into the cabin. This is a major safety defect documented by federal recalls and owner notifications.

Common Symptoms

no warning symptoms before failure
open airbag recall notice
SRS concern only if related components are disturbed during service

How to Fix

Check VIN status through Ford or NHTSA and have the inflator replaced immediately if open recall status exists. There is no maintenance workaround; the only proper fix is recall completion using the updated inflator module. Owners buying used Mustangs should verify recall completion before purchase.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

TipRun the VIN through both Ford and NHTSA recall tools because used cars are often sold before recall work is completed.
TipIf the airbag has been replaced after a collision, verify the replacement was recall-compliant and documented.
UpgradeA simple OBD scanner can help check for unrelated SRS communication issues after interior work, though it does not replace recall service. (ANCEL OBD2 Scanner)
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Typical repair cost:$0 - $0

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Community Reported

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On the 2005-2010 Ford Mustang, on 2005-2010 Mustangs, the passenger seat occupant classification system (OCS) can fail or become inaccurate, illuminating the airbag warning lamp and causing the passenger airbag to be disabled. Ford issued Customer Satisfaction Program 15B24 for certain vehicles because the OCS may not properly detect an adult occupant. Owners commonly report an airbag light, 'pass airbag off' staying on with an adult seated, and failed state inspections.

This issue also affects: Toyota Sienna

Common Symptoms

Airbag warning light illuminated
Passenger airbag off indicator stays on with adult passenger
SRS fault messages
Failed safety inspection due to airbag light

How to Fix

Scan the restraints control module for OCS-related faults and verify passenger seat weight sensor operation with IDS or equivalent capable scan tool. Repair typically involves replacing the passenger seat cushion/OCS mat or related seat sensor components, then performing the required OCS calibration procedure. Wiring under the seat should also be inspected for connector damage or high resistance before replacing parts.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

TipBefore replacing the seat mat, inspect and reseat the under-seat connectors; intermittent resistance issues can mimic a failed OCS.
TipUse a scan tool that can perform OCS zeroing/calibration after repair; simply clearing codes is often not enough.

Typical repair cost:$700 - $1,800

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Community Reported

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On the 2005-2010 Ford Mustang, s197 Mustangs from the mid-2000s have a documented pattern of fuel tank cracking or leaking, often near the seam or around the evaporative emissions components. Owners report strong fuel odor in garages, visible dripping after fill-ups, and EVAP-related warning lights. Because the issue involves fuel leakage near the rear of the vehicle, it presents a fire risk and can require full tank replacement.

This issue also affects: Chevrolet HHR, Ford Ranger, Infiniti QX60

Common Symptoms

strong gasoline smell near rear of car
fuel dripping or wetness around tank area
check engine light
fuel smell after refueling
failed emissions or EVAP test

How to Fix

Inspect the tank shell, seams, filler neck area, and EVAP connections with the tank partially filled and under smoke test if needed. Replace the fuel tank if cracked; also inspect/replace damaged seals, vent valves, and straps as needed. Clear EVAP codes and verify no leaks remain after repair.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

TipDo not keep driving with a raw fuel smell near the rear of the car; inspect immediately and avoid parking in enclosed spaces until repaired.
TipIf the tank is being replaced, inspect the filler neck seal and EVAP hoses at the same time because brittle components can trigger repeat leak codes.
UpgradeA smoke machine helps confirm whether the leak is from the tank itself or from EVAP hoses and seals. (AUTOOL EVAP Smoke Machine Leak Tester)
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UpgradeWhen servicing the tank area, owners often replace aged vapor hoses and clamps to prevent recurring EVAP leaks. (Gates Fuel Vapor Hose)
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Typical repair cost:$900 - $1,800

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On the 2005-2014 Ford Mustang, a common S197 complaint is front-end clunking or popping over bumps, driveways, and low-speed turns caused by worn upper strut mounts, strut bearings, or sway bar end links. The issue is widely discussed in owner forums and often appears as mileage accumulates or after lowering springs are installed. Owners describe a loose-feeling front suspension and knocking noises that can be difficult to isolate without chassis-ear or pry-bar inspection.

Common Symptoms

front clunk over bumps
popping noise when turning into driveways
knock from front suspension at low speed
loose or unsettled front-end feel

How to Fix

Inspect front strut mounts, bearings, sway bar end links, control arm bushings, and spring seating. Replace worn mounts and links in pairs, then perform an alignment if struts or mounts are removed. On lowered cars, verify correct end-link preload and that springs are properly indexed in the perches.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

TipDo not assume the noise is the steering rack; worn end links and upper mounts are much more common and cheaper to fix.
TipIf one front mount or link is bad, replace both sides to keep handling and ride quality balanced.
UpgradeHeavy-duty end links are a common upgrade when the factory links start knocking, especially on lowered cars. (Moog Sway Bar End Link)
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UpgradeReplacement strut mounts and bearings are often installed together to eliminate persistent front popping noises. (KYB Strut Mount Kit)
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Typical repair cost:$250 - $900

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On the 2005-2010 Ford Mustang, s197 Mustangs are known to suffer from water intrusion at the cowl/windshield area that reaches the Smart Junction Box (SJB)/fuse box, leading to erratic electrical behavior. Owners report inoperative or self-activating wipers, lighting faults, battery drain, no-start conditions, and multiple unrelated electrical issues after rain or car washes. Ford published service information addressing water leak diagnosis and SJB-related corrosion concerns on these cars.

This issue also affects: Ford Mustang Mach-E, Ford Focus

Common Symptoms

Wipers operate by themselves or stop working
Headlights or interior lights malfunction
Battery drain after rain
Intermittent no-start
Multiple electrical accessories acting erratically

How to Fix

Inspect the passenger-side cowl, windshield seal area, body seams, and SJB/fuse box for signs of moisture, corrosion, or water tracks. Repair involves correcting the leak path, cleaning or replacing corroded connectors, and replacing the SJB if internal damage is present. Drain paths and cowl seals should be restored so the replacement module is not damaged again.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

TipPull the passenger kick panel and inspect the SJB area for dried water marks before buying modules; many owners find the leak source first, then replace the box.
TipUse electrical contact cleaner and a small terminal brush on mildly corroded connectors, but replace any connector with heat damage or green copper spread.

Typical repair cost:$250 - $1,400

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On the 2005-2010 Ford Mustang 4.0L SOHC V6, the 4.0L SOHC V6 used in 2005-2010 Mustangs commonly develops coolant leaks from the composite thermostat housing and related seals. The plastic housing can warp or crack with age and heat cycling, causing external coolant seepage and sometimes overheating if the leak worsens. This is a well-known issue across Ford applications using the same 4.0L engine and is frequently documented in owner forums and repair databases.

This issue also affects: Volkswagen Eurovan, Audi A7, Audi Q5

Common Symptoms

Coolant smell from engine bay
Visible coolant leak near thermostat housing
Low coolant warning or reservoir level dropping
Engine running hot or overheating
White residue around housing seams

How to Fix

Pressure-test the cooling system and inspect the thermostat housing assembly, crossover area, and sensor ports for seepage or crusted coolant residue. Replace the thermostat housing assembly with updated parts, install new seals, and refill/bleed the cooling system properly. If overheating occurred, verify there is no secondary damage such as a stuck thermostat or compromised temperature sensor.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

TipMany owners replace the complete housing assembly rather than only the gasket because the plastic body itself often cracks.
TipUse a cooling-system pressure tester on a cold engine; small leaks often show up at the housing seam before they drip to the ground.

Typical repair cost:$250 - $700

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Frequently Asked Questions

What are the most common Ford Mustang problems?

According to Au7o's analysis of 0+ owner reports, the 2005-2005 Ford Mustang has 6 documented issues. The most frequently reported are: Fuel Tank Cracking and Fuel Vapor/Fuel Leak at Tank Seam or EVAP Area, Takata Driver Airbag Inflator Rupture Risk, S197 Passenger Seat Occupant Classification Sensor Fault Causing Airbag Warning and Disabled Passenger Airbag. Of these, 3 are rated critical and should be addressed promptly.

Is the Ford Mustang reliable?

The 2005-2005 Ford Mustang has 6 known issues documented across 0+ owner reports. 3 issues are rated critical: Fuel Tank Cracking and Fuel Vapor/Fuel Leak at Tank Seam or EVAP Area and Takata Driver Airbag Inflator Rupture Risk and S197 Passenger Seat Occupant Classification Sensor Fault Causing Airbag Warning and Disabled Passenger Airbag. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Ford Mustang problems?

Repair costs for known Ford Mustang issues range from $0 to $1,800, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Fuel Tank Cracking and Fuel Vapor/Fuel Leak at Tank Seam or EVAP Area, typically costs $900-$1,800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2005-2010 Ford Mustang Fuel Tank Cracking and Fuel Vapor/Fuel Leak at Tank Seam or EVAP Area?

S197 Mustangs from the mid-2000s have a documented pattern of fuel tank cracking or leaking, often near the seam or around the evaporative emissions components. Owners report strong fuel odor in garages, visible dripping after fill-ups, and EVAP-related warning lights. Because th… Repairs typically run $900-$1,800. Severity: high.

What is the 2005-2014 Ford Mustang Takata Driver Airbag Inflator Rupture Risk?

Many 2005-2014 Mustangs were included in the Takata airbag inflator recalls. The driver airbag inflator can degrade over time, especially in hot and humid climates, and may rupture during deployment, sending metal fragments into the cabin. This is a major safety defect documented… Repairs typically run $0-$0. Severity: high.

What is the 2005-2010 Ford Mustang S197 Passenger Seat Occupant Classification Sensor Fault Causing Airbag Warning and Disabled Passenger Airbag?

On 2005-2010 Mustangs, the passenger seat occupant classification system (OCS) can fail or become inaccurate, illuminating the airbag warning lamp and causing the passenger airbag to be disabled. Ford issued Customer Satisfaction Program 15B24 for certain vehicles because the OCS… Repairs typically run $700-$1,800. Severity: high.

What is the 2005-2014 Ford Mustang Front Strut Mount and Sway Bar End Link Clunking on S197 Suspension?

A common S197 complaint is front-end clunking or popping over bumps, driveways, and low-speed turns caused by worn upper strut mounts, strut bearings, or sway bar end links. The issue is widely discussed in owner forums and often appears as mileage accumulates or after lowering s… Repairs typically run $250-$900. Severity: medium.

What is the 2005-2010 Ford Mustang 2005-2010 Smart Junction Box Water Intrusion Causing Wiper, Lighting, and Electrical Malfunctions?

S197 Mustangs are known to suffer from water intrusion at the cowl/windshield area that reaches the Smart Junction Box (SJB)/fuse box, leading to erratic electrical behavior. Owners report inoperative or self-activating wipers, lighting faults, battery drain, no-start conditions,… Repairs typically run $250-$1,400. Severity: medium.

What is the 2005-2010 Ford Mustang 4.0L Cologne V6 Thermostat Housing Cracking and Coolant Leaks?

The 4.0L SOHC V6 used in 2005-2010 Mustangs commonly develops coolant leaks from the composite thermostat housing and related seals. The plastic housing can warp or crack with age and heat cycling, causing external coolant seepage and sometimes overheating if the leak worsens. Th… Repairs typically run $250-$700. Severity: medium.

All 6 Known Issues

When Issues Typically Appear

2005-2014 Ford Mustang: Takata Driver Airbag Inflator Rupture Risk#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2005-2010 Ford Mustang: S197 Passenger Seat Occupant Classification Sensor Fault Causing Airbag Warning and Disabled Passenger Airbag#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2005-2010 Ford Mustang: Fuel Tank Cracking and Fuel Vapor/Fuel Leak at Tank Seam or EVAP Area#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2005-2014 Ford Mustang: Front Strut Mount and Sway Bar End Link Clunking on S197 Suspension#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2005-2010 Ford Mustang: 2005-2010 Smart Junction Box Water Intrusion Causing Wiper, Lighting, and Electrical Malfunctions#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2005-2010 Ford Mustang: 4.0L Cologne V6 Thermostat Housing Cracking and Coolant Leaks#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

Other Ford Models

Frequently Asked Questions

What are the most common Ford Mustang problems?

Is the Ford Mustang reliable?

How much does it cost to fix common Ford Mustang problems?

What is the 2005-2010 Ford Mustang Fuel Tank Cracking and Fuel Vapor/Fuel Leak at Tank Seam or EVAP Area?

What is the 2005-2014 Ford Mustang Takata Driver Airbag Inflator Rupture Risk?

What is the 2005-2010 Ford Mustang S197 Passenger Seat Occupant Classification Sensor Fault Causing Airbag Warning and Disabled Passenger Airbag?

What is the 2005-2014 Ford Mustang Front Strut Mount and Sway Bar End Link Clunking on S197 Suspension?

What is the 2005-2010 Ford Mustang 2005-2010 Smart Junction Box Water Intrusion Causing Wiper, Lighting, and Electrical Malfunctions?

What is the 2005-2010 Ford Mustang 4.0L Cologne V6 Thermostat Housing Cracking and Coolant Leaks?