Four problems related to brake hoses, lines/piping, and fittings have been reported for the 2002 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2002 Ford F-150 based on all problems reported for the 2002 F-150.
Both the rear spring shackles as well as the brake lines have failed on my 02 Ford f150 due to rust and this is a common concern. I am a senior master technician for Ford and we repair these on a regular basis due to rust. Both are clear safety concerns when they fail and should be addressed. And with the Ford windstar axles and subframes being covered by a recall due to rust I do not understand why other rust related safety concerns are not recalled. If one rust related concern is recalled then all others should be as well, it should be all or none. On the rear spring shackles, they will snap in half and the rear eyelet of the leaf spring jams into the bottom of the truck bed, with the bed being the only thing keeping major damage or an accident from happening. On the front brake lines, the rust and swell up under the rubber part of the line where the lower steel line is inserted into the rubber. On hard brake application the line blows and you lose front brakes. Both are common concerns on trucks in new england wher rust is a part of life. If I wasnt a tech that drives vehicles with failed brakes and broken suspensions on a regular basis, both of these failures could have caused a major accident and likely injuries.
The car was stopping to drop off mail at a mailbox. The brake pedal went all the way to the floor. Inspection revealed brake fluid on the gas tank. A rusted brake line was the cause. Dealer replaced the line at cost of $511. 95 including brake fluid flush. The rear brake line was replaced. It runs from the front to the back.
Mid vehicle frame location brake line burst due to rusting out while backing an RV into a camping site. Lost all braking fluid and brakes. Had just completed traveling two hours on interstate highways towing a 3,500 lb. Trailer. I was very lucky that failure occurred while backing the trailer at almost no speed and parking brake stopped the truck. Decided to report this failure after vehicle was just recalled due to rusting gas tank straps. Frame of vehicle is badly rusting and Ford must do more to prevent frame and undercarriage components from rust out due to winter driving conditions. .
The contact owns a 2002 Ford F-150. While stopped at a traffic light, the brakes failed. The contact had to depress the brake pedal to the floor and apply the emergency brake in order to stop the vehicle. He discovered brake fluid leaking from the center between the rear wheels. The vehicle was towed to the mechanic and they stated that the emergency brake cable was rubbing against the normal brake line, causing the cable to fail. The vehicle was repaired. The manufacturer took a complaint and forward it to the proper office. The current and failure mileages were 148,000. Updated 02-14-08.