Three problems related to brake disc caliper have been reported for the 2011 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2011 Ford F-150 based on all problems reported for the 2011 F-150.
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.
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.
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.