Two problems related to brake disc caliper have been reported for the 2006 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2006 Ford F-150 based on all problems reported for the 2006 F-150.
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.
Truck began shuddering when braking @ low/high speeds. Was told rotors warped @ approximately 6,000mi. Dealership had the rotors machined and then adjusted calipers. After driving truck off noticed brake pedal was slightly softer but no longer felt vibration/shuddering. At approximately 9,000mi once gain felt slight shudder/vibration when braking. Took truck to dealership with approximately 13,000mi and was told rotors were once again warped. I had ceramic brakes installed @ approximately 24,000mi and new rotors installed @ approximately 30800mi. With the rotors installed significant vibration still occurs when braking at any speed. Safety concerns for some time now. Apparently shuddering not due to warped rotors as dealership suggested.