Brake Disc Caliper Problems of Ford F-150 - part 2

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.

See all problems of the 1997 Ford F-150 🔎.

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.

See all problems of the 2005 Ford F-150 🔎.

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.

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.

See all problems of the 2007 Ford F-150 🔎.

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.

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.

See all problems of the 1999 Ford F-150 🔎.

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.

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.

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.

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.

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.

See all problems of the 2004 Ford F-150 🔎.

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.

On August 24, 2006, my passenger-side, front, lower caliper mounting bracket bolt backed itself out. This happened at a lower speed (about 20-25 mph) and so there were no injuries involved (especially since I had three passengers in the vehicle). But, when this happened it gouged the inside of the wheel (a factory wheel) and caused it to instantly deflate the tire as I came to a stop. I ended up having to replace the wheel, the rotor and the brake pads to fix the damage. On October 18, 2006, while traveling nothbound on I-25, just north of exit 158, I heard a "popping" sound and felt as if I had run over a rock. I then took exit 161, and while traveling about 25-30 mph, and stopping, my front, driver's-side, tire suddenly exploded from a huge gash in the sidewall. I was towing a 8'x10' flatbed trailer with some tools loaded on it. When I was able to get out of the traffic lanes, I removed the tire and the entire wheel had split in two. I also discovered that again, the lower caliper mounting bracket bolt had backed itself out. I had to have the vehicle towed and the tow truck driver told me that he knew of this happening to other people after they had their Ford pickup brakes worked on. He said that it is not a problem, that he knew of, when the vehicles come from the factory, only after the brakes have been worked on. I had to replace the wheel, the tire, the steering knuckle, the rotor and the pads. We ended up replacing the lower bolts and putting locktight on the bolts (this was the recommendation from the tow truck driver and my mechanic). We did save the damaged parts. After the first incident my mechanic checked the tech service bulletins and did not find any bulletins from Ford this issue. I also spoke to the parts service rep at phil long Ford (colorado springs, CO) and he told me that he knew about this issue, that it was actually quite common, but that Ford had not issued a bulletin about this.

See all problems of the 2002 Ford F-150 🔎.

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.

See all problems of the 2006 Ford F-150 🔎.

The contact owns a 2005 Ford F-150. While driving 50 mph, the rear calipers froze. The wheels began smoking and the vehicle was taken to the dealer. They stated that there was a malfunction with the calipers. The dealer also discovered that an axle seal was leaking, which saturated the brake fuse for the emergency brake. The dealer replaced the seal and calipers and turned down all four rotors on the vehicle, but did not replace the brake pads. The failure recurred and the dealer replaced the rear calipers, rear rotors, and brake pads. The contact wanted to charge him for the brake pads (parts, not labor). The current mileage was 29,250 and failure mileage was 12,500. Updated 4/2/08 updated 04/02/08.

Failure of rear calipers on 2004 Ford F-150 truck causing tires to lock up or violent shaking in front end.

While traveling on I-10 vehicle vibrated violently. Once while traveling approximately 55 mph and once at 65 mph. During the incidents the vibration was not isolated to one part of the vehicle but the whole vehicle vibrated. After inspecting the vehicle the next day in daylight I noticed the following: 1. All wheel rims were completely covered with brake dust. Even though I had just washed the vehicle prior to starting the 1,000 mile trip from houston, TX to green cove springs, FL. 2. All wheel rims had what was either brake fluid or melted wheel grease on the surface. 3. All four tires were damaged by the vibration I. E. , tread had started to delaminate from the tire. Tires had approximately 28,000 miles at the start of trip and were in good condition with no tire worn to wear bar. 4. All four tires had scuff marks that appeared as if the tires had been run low on air. 5. The front rotors on the outside surface were the brake pad made contact were grooved beyond what should have been present on a vehicle with 29,000 miles on the odometer. Metal shavings were present on the front wheel rims. 6. The rear rotors were also grooved on the outside with the inside appearing as if the brake pad was not making contact with the rotor surface I. E. , only outside pad is making proper contact. I took the 2004 Ford F-150 to the Ford dealer located in green cove springs, FL for correction of the above problems. Service manager initially resisted admitting that anything was wrong with the vehicle until a maintenance tech walked by and said he had a "TSB on that". Dealer subsequently replaced the front rotors, calipers, and pads. However, the service manager would not admit the vibration caused the damage to the tires. The rear calipers, rotors, and pads were not serviced or changed. Further, the service manager could not or would not admit to original problem with the vibration being fixed.

I had to replace my brake rotors and calipers due to corrosion after only 18000 miles, and again after about 35,000 and 60,000 miles due to corrosion. On two occasion, this problem was discovered when the brakes completely locked up and the vehicle could not move. Much of my driving is on snow-covered roads with road salt, but I routinely use a car wash with undercarriage wash frequently -- about once per week. Is there no technology to increase the corrosion resistance of these critical safety parts?.

While driving my 2005 f150, the passenger side rear tire started locking up and smelling really bad. I stopped to investigate and found the rim to be very hot. I drove it a few more miles to a local Ford dealer. They said they were going to loan me a car for free and fix the problem. I asked what problem and they said the problem they have started having with f150 brake calipers locking up while customers are driving. It bothers me that I had to find out about the problem this way. I think Ford should be telling customers about this problem right now before someone gets hurt bad from this defect.

2004 f150 brakes began to shimmy and shutter 3 months after purchase. Rotors and brakes were resurfaced and replaced. ** answer required*** about three months after the vehicle was purchased the consumer began have problem with the brakes. The dealer has replaced the rotors 3 time, resurfaced them twice, replaced the brake pads three times and replaced the front calipers once. The rear end was replaced on Dec 2, 2004 because of vibration and bad bearings.

Brake were not right spongy. Wearing out bake pad's nothing happened yet but not working right as of now. I replaced caliper and pad's. And brakes are still dragging.

See all problems of the 1998 Ford F-150 🔎.

1999 F-150 front brakes locking up/failure to release properly, brakes dragging.

The 2004 f150 and I assume expeditions had undersized front brake rotors and calipers and were outlined in a service tech bulletin for the purpose of diagnosing the front end shaking/shimming during braking. This is my opinion should have fallen under a mandatory recall due to the serious nature of poor engineering. No recall and out of pocket $$$. The same holds true for the rear differential which in my case has been replaced (3) times and again Ford published a tech bulletin outlining the fact that the '04 rear differential housing was subject to faulty machining causing rapid wear on ring/pinion and bearings. I believe these two defects should have been addressed due to the fact that failure of either component could result in a serious accidents. I truly believe Ford tried to cover up/white wash these defects. I still have this '04 and still have issues with the brakes and rear differential not to mention a host of other issues that have plagued this particular year model. I look forward to hearing from someone and would like to know the extent of Fords involvement and any accidents involving '04f150's. Best regadrs.

While driving 55 mph front brake caliper assembly fell off. As a result, the vehicle came to a screeching halt and had to be towed. Dealer stated that caliper bolts backed out and fell out.

See all problems of the 2001 Ford F-150 🔎.

The contact owns a 2004 Ford f150. While driving 60 mph, the vehicle's steering wheel and front end shake. The rack and pinion was replaced at 48,000 miles, the rotors were replaced and turned several times, and the calipers were replaced as well. However, the failure persists. While driving over 40 mph and making a sudden stop, the brake pedal goes all the way down to the floor and the vehicle eventually stops. The brake pedal must continuously be pumped for pressure while driving. The dealer stated that the brakes are normal. The vehicle has been experiencing the failures since the date of purchase. The current mileage is 51,000 and failure mileage was 2,000.

The two mounting bolts for the front brake calipers come loose. It has happened twice, in each case it has occurred on the left and right front calipers. Both times it has happened after a brake job. After approximately 200-300 miles on the new pads, the caliper bolts can be re-tightened and do not come loose again.

We have a 1998 Ford f150 that was purchased in 2001 equipped with anti-lock brakes. Yesterday they locked up prematurely while driving on the highway. It started with a burning metal smell & started to shake & vibrate. We couldn't go over 40 mph. It's quite fortunate that there was an auto repair shop on a nearby corner where we stopped, and discovered that the break pads were fine; however, the passenger side caliper was locked up.

At highway speed (70 mph) in left lane of 4 lane divided highway ( conditions dry) was required to perform emergency braking due to slow moving vehicle pulling into our lane. Felt abs braking (pulsing) for about 1-2 seconds and then truck whipped 90 degrees to the right. Skidded across highway, straighten up, but slid off right shoulder into ditch. Only minor damage to truck. On the highway there was visible a skid mark for right side of truck at the point of braking (no skid marks for left wheels) and skid mark across the highway at about 45 degree angle. Truck had previously been to dealer twice in previous 2 months with complaint about brakes being rough on release. Returned truck to dealer on 2/15/03 and dealer kept until 2/19/03 and reported there was nothing wrong with the brakes. Met with dealer service manager on 3/3/03 and service manager and Ford engineer today (3/4/03) and we could not duplicate problem on several attempts at 50-60 mph. Engineer admitted there were only a couple of things that would cause right brake to lock up, abs module or caliper. Asked what I wanted and I asked them to replace abs module and caliper. They refused.

2001 Ford f150 supercrew. Took the vehicle to the dealer to check the tire tread for excessive wear and front aligment. First dealership said it was due to aggressive driving. In 2 years I have replaced the brakes 5 times, the rotors 3 times and I am on my 3rd set of calipers.

While driving and brakes were applied, vehicle pulled to right and brakes starting squeaking. The dealership indicated that the this was caused by the equipment that holds the brake calipers breaking, which left the caliper not mounted. Ts.

Right front bolts that hold brake caliper on fell off. Vehicle came to a abrupt stop. Two weeks later, left front brake caliper fell off. This time it poked a hole in tire, and could have caused a dangerous accident.

Our insured, mr mohssin, performed an evasive manuever at highway speed applying the brakes to the maximum while turning. His 2001 f150 harley edition is equipped with abs as well as 20" rims which are 40lbs heavier than stock. In the last several weeks, we have gathered sufficient evidence to suggest that the lf and rf brake caliper brackets snapped during this loss causing both tire/wheel/hub assys to shear off the spindle nuts and become separated from the vehicle. There was no impact with any other vehicle prior to this and all components on this vehicle are oem. It is the opinion of our indpendent reconstructionist engineer that there is ample reason for Ford to be concerned and review the evidence for themselves. To date, we have had no luck getting any response or interest in reviewing our findings. Many avenues have been pursued to seek some response. The only contact so far has directed us to submit a subrogation demand if we seek recovery. Our concern at this point is to get the insured his vehicle back. Physical evidence has been secured. Repairs will begin the first week of July. We would appreciate it if the NHTSA could persuade a Ford representative to contact our ncal pd mgr, eric hacker at 916 853-4607 to confirm Ford's position. We appreciate any assistance you can provide.

Driving at 30-35 mph when left brake calipier locked up causing rim and rotor to get red hot. Consumer stated that if he was driving at a higher rate of speed tire would have blown out.

Brakes not effective under moderate hard braking. They make a clacking noise. Seems as though the abs is not allowing the calipers, shoes and pads to work as one unit.

Truck has front abs brakes and rear brakes are drums, when brakes are applied, the trucks front end vibrates, vibrations occur at any speed with probable cause being brake caliper, owner also identified a burning smell or overheating of brakes.

See all problems of the 1996 Ford F-150 🔎.