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Brake Disc Caliper Problems of Ford F-150 - part 1

Ford F-150 owners have reported 48 problems related to brake disc caliper (under the service brakes category).

car image   Brake Disc Caliper problem of the 2013 Ford F-150 1
Failure Date: 08/07/2014

Loud screeching. Took it to my local mechanic and was told to take my truck to Ford. My calipers may be calibrated incorrectly. The wheels were taken off and the drivers side brakes were engraved due to the metal on metal braking. My finger would be able to fit into the the deep engraved scratch on that brake. The passenger side was not the same but the mechanic said that it was going to happen soon if it's not taken care of quickly. I was told that the brakes, brake pad and rotors were completely ruined. To my amazement the dash board controls state that my brakes are fine. My mechanic said this is a manufactures defect and needs to be seen by Ford.

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car image   Brake Disc Caliper problem of the 2006 Ford F-150 2
Failure Date: 07/18/2014

As a part of regular maintenance I always have well in advance preformed scheduled maintenance on my 06 F-150. On Aug 23 2013 I had my rotors and brake pads all replaced as well as having a hi pressure brake fuild change performed as part of this as suggested by the bill currie Ford dealership in tampa. The truck had 83,996 miles on it at this time of service. The truck was rarely driven after that and used only on short trips. Of 10-20 miles or less after having the brakes serviced. Friday July 18th 2014. . The tuck had only approx. 2000 additional miles on it after the brakes were serviced at bill currie Ford. I and a friend were driving to pickup a washing machine about 30 miles away. Without warning. Upon returning the right wheel began pulling to the right and smoke and a rubber and plastic smell accompanied by smoke starting rising from the right wheel well which was scotching hot. The heat was so intense that when we stopped the plastic wheel cover fell off because its was melted. It was taken to the dealership were the original work was performed. I was informed it was the caliper,that it had seized and that after already having replaced the front rotor several thousand miles before//the right rotor and caliper and brake line would now have to be replaced again. . Because they said. . "we can't tell when a caliper will fail". Now it has cost me $2,300,00 to get my brakes done. . When initially they were still in safe limits. We were lucky this didn't cause a fire or cause the tire to blow out while on the highway.

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car image   Brake Disc Caliper problem of the 2010 Ford F-150 3
Failure Date: 05/30/2014

I was traveling along interstate-10 when I detected a the odor of what I thought was brake pads burning. As I pulled over to the side of the road the front end of my truck didn't respond as it normally would turning and I thought my brakes were locking up. I came to a complete stop and put my flashers on and exited my vehicle to inspect my front end. When I approached the front drivers side tire I could smell the something burning and I could feel and extreme amount of heat coming from the tire well area. I noticed the brake calipers were smoking and when I reached down and touched my wheel rim it was so hot it burnt my hand. I later jacked up the front of my truck to inspect caliper and found it completely locked up and wheel would not turn at all. I had to call for assistance and get it to a shop where I found out that there was a TSB Ford put out. I feel like my life was put in danger because I was not warned about this TSB and the brake problems Ford is experiencing. I am extremely angry that Ford has not made this problem more widely known and I find it disturbing that I have to search out, on my on, potential life threatening issues with my vehicle. Please do something about this problem.

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car image   Brake Disc Caliper problem of the 2011 Ford F-150 4
Failure Date: 05/23/2014

Severe vibration and pulsing when brakes were applied. I put the truck on my lift and tried to rotate the front wheels, there was severe brake drag, which made rotating the front wheels close to impossible. I removed the wheels and did a visual inspection and found that the inner brake pads were considerably more worn than the outer pads. I then removed the calipers and found that corrosion occurred binding the inner pads to the brake pad holders. I live in the north east and road salt is used in the winter months, this should be taken into consideration when the brakes are designed so that this corrosion can't occur. I corrected the problem by re-placing the rotors and brake pads, using brake lubricant to help prevent the corrosion. Doing this repair corrected the problem.

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car image   Brake Disc Caliper problem of the 2011 Ford F-150 5
Failure Date: 06/23/2013

When my steering started to shake when I applied the brakes I removed the wheel and brake calipers to inspect them. The inside rotor surface is not as wide as the outside so the brake pads do not contact the entire surface of the rotor like the outside. It looks to me like the rotor was defective when installed. The brakes have 41000 miles on them and are less than half worn out. They are the original brakes.

car image   Brake Disc Caliper problem of the 2011 Ford F-150 6
Failure Date: 06/14/2013

At times, I experience a soft brake pedal that will travel almost to the floor. And then at times I will have a harder pedal without the possibility of the pedal traveling to the floor. I have had the brake fluid flushed and this still happens on occasion. I have gone through 3 sets of brake pads on the front of my truck in 60,000 miles. I can hear the secondary pump run for a longer duration at times during start up and if I pump the brakes while stopped with the engine running. When I experience a soft pedal it travels much further before I would come to a stop compared to the harder pedal feel. Also, at times it feels as if the harder pedal needs more force to experience any "normal" braking power. After experiencing this situation, then some time later I would experience a normal brake pedal. I have had my vehicle serviced at the dealer for this situation for abnormal brake wear and pedal feel, but still have had no fix for the issue. I just replaced a front brake caliper and I am currently waiting to see if this resolves the issue.

car image   Brake Disc Caliper problem of the 2010 Ford F-150 7
Failure Date: 05/02/2013

The contact owns a 2010 Ford f150. The contact stated while driving 65 mph, the brakes locked and the calipers were red. The vehicle was taken to the dealer for inspection and they could not determine the cause of failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 114,000.

car image   Brake Disc Caliper problem of the 2001 Ford F-150 8
Failure Date: 10/17/2012

Truck starting pulling badly to right, loss of power, speed and smoke coming from the right front wheel. Rim, caliper were smoking , had to pour water on to wheel to keep from burning. After towed to service center was told this is a common problem with the Ford trucks that the slide pin on the caliper can seize and lock the brake in active position preventing it from releasing from the rotor causing the the extreme heat and burning the brake bad and seals in the caliper. I was lucky it didnt happen at 70 mph and lock the wheel causing me to lose control. I ve also looked at the reports on the internet and see where others have reported this in blog but now to safety commision.

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car image   Brake Disc Caliper problem of the 2002 Ford F-150 9
Failure Date: 04/04/2012

Front brake caliper mounting bracket seized on the slide bolts that allow the brakes to move in and out when pressed and released. The slide bolts that allow the caliper to move have seized causing the vehicle to pull very hard to one side of the road. In my case I was towing a 20' commercial landscape trailer equipped with dual axle trailer brakes. I approached a traffic light and proceeded to make a left turn going a speed of approximately 15 to 20 mph when I pressed the brake during the turn the truck pulled extremely hard to the left resulting in my trailer jack knifing into the left side of the truck causing major damage to my bed and rear wheel on my truck. Later after investigating the cause of the sudden pull found that the left brake caliper mounting bracket had one of the bolts seized while the other was moving properly allowing the brake to move a little but not properly causing the brake to drag against the rotor on the inner brake pad. When the brake is pressed the pressure pulls the truck to the left extremely hard. Replacing the slide bolts and the brake caliper mounting bracket fixed this issue and I haven't had any issues after replacement. I know this may be a little hard to understand as my description may not be the best, but the upper brake caliper bolt was seized while the lower bolt was moving freely, when the brake peddle was pressed caused the left brake caliper to grab harder than the right side causing the truck to pull extremely hard to the left. The trailer brake was set on 7 at the time and worked properly. The truck pulled so hard to the left caused the trailer to be at such a tight angle it began to slide and when I realized what was happening it was to late to correct it. The bed is still damaged from this. Btw I bought my Ford in 2002 brand new with 5. 4 v8 and I am at 271,000 miles and it runs like the day I purchased it! I love it!.

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car image   Brake Disc Caliper problem of the 2004 Ford F-150 10
Failure Date: 10/15/2011

The rear brake lines failed. The rubber line from the caliper to the steel line on the rear axle separated, first on the drivers side and about three weeks later on the passenger side. On the first occasion I was just leaving my garage and on the second occasion I was pulling into a parking spot. The steel fitting that holds the rubber line to the steel line was so badly corroded that it literally disintegrated, allowing the rubber line to separate from the steel line when the brakes were applied.

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car image   Brake Disc Caliper problem of the 1997 Ford F-150 11
Failure Date: 09/29/2011

The contact owns 1997 Ford F-150. The contact stated that after receiving notification of NHTSA campaign I. D. 11v385000 (fuel system, gasoline: storage: tank assembly: mounting) the contact took the vehicle to the dealer. The dealer stated that the fuel straps were corroded. The dealer was unable to perform the recall remedy due to the severity of the corrosion on the fuel tank straps. The contact called the manufacturer regarding the recall repair and was advised that the manufacturer the fuel tank mount would have to be repaired at the contact's expense. The vehicle was not repaired. The failure mileage was 150,000. The consumer stated the frame bracket had rotted and the recall could not be performed. The consumer stated the vehicle has a slight hesitation, there was a noise when the gear was in drive, the brakes felt spongy, the brake line had to be replaced, as well as the brakes, calipers and hoses. Updated 04/17/12 updated 04/25/lj updated 05/02/12.

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car image   Brake Disc Caliper problem of the 2001 Ford F-150 12
Failure Date: 09/17/2011

While returning home, towing 25' pontoon boat, approaching driveway when brake pedal went to floor, no brakes. Fortunately I was able to maneuver the vehicle into my yard and stop with parking brake. Root cause was found to be brake line above driver's side rear wheel had rusted through at fitting causing loss of brake fluid. Upon close inspection, many brake lines, transmission cooling lines, gas tank straps (the latter subsequently replaced per Ford recall) are deteriorating due to excessive rust. Although this vehicle is 11 years old, it only has 58,867 original, documented miles, and has not been exposed to excess road salt (mid-atlantic region). I have had to replace brake rotors, calipers, brake shields, egr tube, exhaust system from muffler back, and parking brake assembly all due to excessive, and what I consider, premature rust. If that were not bad enough, yesterday I look under the truck and see a puddle of transmission fluid. One of the transmission cooling lines between the transmission and the upper radiator has rusted through, and once again I will be responsible for the repairs. I have owned many Ford products in my 44 years of driving but have never experienced anything of this magnitude with a vehicle of such low mileage. Brake lines rusting out should be considered a significant safety concern. If I had lost brakes while traveling on the highway towing a 3000 lb boat and trailer it could have been disastrous. I feel the gas tank strap recall is a start, but far from addressing the overall issue of undercarriage deterioration with this year/model vehicle.

car image   Brake Disc Caliper problem of the 2001 Ford F-150 13
Failure Date: 04/03/2010

2001 Ford f150 2wd, bottom bolt holding left front brake caliper to spindle assembly fell out. Scrubbing sound at braking initiated an investigation of problem and found lower fastener missing and upper fastener loose. The caliper had rotated and cast iron piston assembly was rubbing interior of aluminum wheel. Fortunately I was within three miles of home. Continuing travel had the potential to destroy the wheel and cause further damage or accident. The right side was investigated and both fasteners were in place. The Ford supplied capscrews (bolts) did not have serrated flanged head, did not have lockwashers, did not have thread locking liquid compound applied to threads. Local Ford dealer was closed on Saturday afternoon. All four fasteners were replaced by owner using flanged stainless steel capscrews of the correct thread and length using thread locking liquid compound. Owner has possession of the three fasteners removed. Vehicle mileage 04-03-2010 was 046741. 4 there are reported incidences of this potential defect on the internet which have the ability to cause a crash or damage or death. To my knowledge there has not been a recall issued or potential safety defect sent to vehicle owners.

car image   Brake Disc Caliper problem of the 1997 Ford F-150 14
Failure Date: 02/01/2010

Left front brake line failed catastrophically causing a complete loss of hydraulic braking. Vehicle was stopped using emergency brake. Brake line had corroded through about 2-3 inches from left front brake caliper. Line was replaced but old line was not retained.

car image   Brake Disc Caliper problem of the 2005 Ford F-150 15
Failure Date: 08/10/2009

Had to replace wheel bearing, pads and rotors at 33000 miles. 5000 miles later caliper froze locking brakes. Another brake job had to be done.

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car image   Brake Disc Caliper problem of the 2005 Ford F-150 16
Failure Date: 06/17/2009

2005 f150 4x2 regular cab. . Purchased new from al packerd Ford, royal palm beach, FL. I have noticed a vibration/shudder, from intermittently to continuously on short trips. On longer trips I noticed a couple times an odor of something burning. I brought it to advantage Ford, 4000 se federal highway. Po box 2930, stuart, FL. 34995, phone: 772-287-0955, to have it inspected and they said I needed a brake caliper on the right passenger side. Mileage at time of inspection: 62,701. My concern is that this is a safety defect and a manufacturer defect as well.

car image   Brake Disc Caliper problem of the 2007 Ford F-150 17
Failure Date: 06/09/2009

My truck starting having brakes problems (vibration when stopping) at around 25,000 miles. Took it in to dealership for inspection with 29,000 miles on it. Ended up machining all rotors (not under warranty). I'm now experiencing the same problem at 42,000 miles. I believe the rotors and calipers are severely undersized considering the weight of the truck. I suggest that Ford make good on the next brake job. Had a 88 chevy p/u and went 75,000 miles before replacing the front pads. Ford has erred on it's engineering.

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car image   Brake Disc Caliper problem of the 2005 Ford F-150 18
Failure Date: 04/02/2009

2005 Ford F-150 supercrew with bad shaking/vibration. Consumer states that the dealer replaced the calipers, brake pads, and machined the rotors. Consumer found out about TSB's for this exact problem with the model and model year truck.

car image   Brake Disc Caliper problem of the 1999 Ford F-150 19
Failure Date: 09/01/2008

I was on a trip in alabama traveling south on I-85 on September 2, 2008. I stopped for a break just north of montgomery. When I got on the on ramp to I-85, my left front tire suddenly went flat. I replaced the wheel with the spare and discovered that the wheel had been ripped open. I drove to the nearest Ford dealer in montgomery where they discovered that a brake caliper bolt had come out and caused the brake caliper to rip the wheel apart. I was extremely lucky to have been on the on ramp rather than traveling on the interstate at 70 miles an hour. This is the third time that the same caliper bolt has come out. The last time was in oneonta ala and was replaced by the local Ford dealer in oneonta. This is a dangerous safety problem that could have caused the death of two people.

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car image   Brake Disc Caliper problem of the 2007 Ford F-150 20
Failure Date: 03/01/2008

Brake pedal will fade to floor after stopping. Will fade after holding pressure on pedal for a while . Normal braking seems to be ok. Also had front, right caliper stick and destroy the pad and rotor at 29,000 miles.

car image   Brake Disc Caliper problem of the 2005 Ford F-150 21
Failure Date: 02/08/2008

Returning home from errands Friday evening, my husband noticed a burning smell coming from the back of my truck. Upon further investigation, the right rear passenger tire rim was very hot and there was a strong, burning odor. Not wanting to due further damage, we made an immediate appointment with a local repair shop Saturday morning. The mechanic was surprised he had to replace the right rear passenger caliper, brake pads and the right rear rotor now just makes spec after having to be resurfaced. I am the primary driver of this truck and almost always have my two small children with me. Obviously, there is a problem here that someone needs to address immediately before there are any injuries or deaths. What has to happen to get someones attention and have such a serious safety defect corrected? and let me just add that I only have 23, 500 miles on my truck.

car image   Brake Disc Caliper problem of the 2005 Ford F-150 22
Failure Date: 02/08/2008

I own a Ford F-150 pickup truck. The rear caliper is broken and the front struts are leaking. I only have 34,000 miles on this vehicle. Please e-mail me back with info about this problem. Thank you lionel parent.

car image   Brake Disc Caliper problem of the 2005 Ford F-150 23
Failure Date: 01/21/2008

Severe front brake shudder starting at 40,000 miles: turned rotor, severe brake shudder at 60,000 miles: replace l front rotor and brake pad: severe shudder at 80,000 miles: presently at 110,000 miles and Ford tells me I need to replace the rotors and caliper to solve a problem that Ford knew about before I purchased the new vehicle in Aug 2005 (service bulletin 100117872 June 1 2005). It was not right for Ford to sell me a truck with brakes that were already under a service bulletin.

car image   Brake Disc Caliper problem of the 2004 Ford F-150 24
Failure Date: 12/04/2007

I noticed my brakes pulsating when applied. The dealers service tech told me the front brakes were not releasing fully and had warped the rotors beyond repair. The caliper pistons had "cocked" in their housings, destroying the front calipers. The repair cost over $1,400. The risk is that the brakes would bind, fail to disengage when applied, and cause a crash.

car image   Brake Disc Caliper problem of the 2004 Ford F-150 25
Failure Date: 11/28/2007

The contact owns a 2004 Ford F-150. While driving between 30-50 mph, the front brakes would grind and the brake pedal would pulsate when the brakes were applied. The dealer stated that the pistons in the calipers were misaligned and failed to release the brake rotor. The dealer replaced the rotors and calipers. The current and failure mileages were 27,288.