Brake Hoses, Lines/piping, And Fittings Problems of Ford F-150 - part 2

The contact owns a 1999 Ford F-150. The contact stated that when depressing the brake pedal, the pedal would feel spongy as if the vehicle was not going to stop. The contact would have to continuously pump the brake pedal for the vehicle to come to a complete stop. The contact referenced NHTSA campaign id number: 05v388000 (vehicle speed control) and stated that the vehicle was repaired under the recall but to no avail. The dealer also repaired the leak in the brake line but not the air that was being released and causing the brakes to not perform properly. The manufacturer was notified of the failure but advised the contact that the defect was not directly related to the recall. The failure and the current mileage was 204,000.

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My truck front cross member that supports radiator and the body to the frame is just about rusted gone. Dealer stated that truck is 11 years old and will not fix. I am sending this for record in the event I am killed due to any failure. Have read two cases on your website. One is a 2000 F-150 that a cross member support rusted out in 2003 with 48,000 miles. Another was a 2000 F-150 that had a tag attached to the frame stating defective material do not use! l/s performance . I expect a full investigation on this and want my vehicle inspected. The consumer was informed the brakes lines needed to be replaced as the vehicle was unsafe to drive. Updated 01/06/12.

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Was going to Ford dealer for gas tank strap recall due to straps that have poor corrosion protection. As I was enroute to dealer I applied my brakes due to a car running a stop sign and my brakes gave way and I just missed a serious accident. I checked my brake line where the leak was and due to very poor rust the line blow out. I ask the dealer when performing the recall repair could he fix the line and was stated a 600. 00 charge. While at the dealer I called Ford vp of customer service fred toney who then sent me to mr. Fedders. I talked to a person from his office and told them that Ford has a big problem on brake lines rusting and because of that I just missed having a serious accident. I ask Ford to fix the linings at no charge and take the line for observation. I was told that since the truck is 10 years old and has 200,000miles on it they will not do anything. I stated that Ford has no problem repairing the gas straps of a 10 year old truck. Anyway had my truck towed to my mechanic and repaired. They replaced the front lines and intermediate brake lines due to poor corrosion. I was told my passenger side line and both rear lines are in great shape, no rust and coated. I told Ford about this and said I want a Ford rep to inspect my coated brake lines. And my defected line which I kept for proof. I ask Ford why some line were coated and some were not. I was told that Ford does not coat the lines. We have a serious problem here and could result in many deaths. If the other lines were coated I would have not had this problem. Ford just wrote this whole thing off. I expect NHTSA to get back to me as soon as possible. I expect my truck to be inspected and the line that I have kept to be inspected. I am now notifying NHTSA and Ford has been notified about this problem and is on recored in the event nothing is done and people get killed the parties will have a problem.

The contact owns a 1999 Ford f150. The contact was attempting to park the vehicle. As the brakes were applied, the brake pedal was abnormally depressed into the floorboard. After inspecting the failure he noticed corrosion and rust on the brake line and the fuel straps. The dealer was notified of the rust and informed the contact there were no recalls and offered no further assistance. The manufacturer was also notified who offered no assistance. The failure mileage was 100,000.

The contact owns a 1997 Ford F-150. The contact was driving 60 mph when he tried to engage the brakes and the pedal was depressed abnormally into the floorboard. The contact mentioned that he had to shift into neutral to engage the emergency brakes in order to stop the vehicle. The vehicle was taken to a local mechanic who diagnosed that the brake lines ruptured as a result of corrosion. The manufacturer was not made aware of the failure. The vehicle was repaired. The failure mileage was 85,000 and the current mileage was 86,500.

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The contact owns a 1998 Ford F-150. While driving approximately 30 mph the contact depressed the brake pedal. The brakes did not respond and the contact crashed into a vehicle. A report was filed. The vehicle was towed to a repair shop where the mechanic stated the brake line was rusted. One of the fuel tank straps were covered with rust and the other strap was broken. The brake lines were replaced. The fuel tank straps were not repaired because the part was not available and had to be ordered. There was a NHTSA recall campaign number: 11v385000 ( fuel system, gasoline:storage:tank assembly:mounting) that may be related to the failure. The contact was unaware if the VIN was included in the recall. The VIN was not available. The vehicle was not repaired. The approximate failure mileage was 170,000.

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Brake failure while driving due to corroded brake line above fuel tank. No warning lights prior to or after failure.

Failure was immediate, Ford f150 fuel tank straps. While driving down the road apparently the tank straps gave way and the fuel tank dropped. Before coming to a stop and after catching some uneven pavement, fuel tank was pealed open and losing about 8 gallons gas. Fire dept was called and they cleaned up spill. Both straps broke and fuel tank is un-repairable. Updated 08/05/11 the consumer stated he experienced other problems with the vehicle, such as a leaking power steering gear box, brake lines had to be replaced, there was a leak in the 4-wheel drive gear box, the muffler hangers, ball joints, tie rod ends and shocks all had to be replaced. Updated 08/11/1.

While braking to turn, the brake pedal went to the floor and I was unable to stop. Luckily I was already slowing for the turn and was able to downshift to slow enough for the turn. Mechanic said the brake line was rusted through. With the recent recall of rusted gas tank straps on this vehicle, believe a recall on rusted brake lines is also warranted. This could have been a fatal accident under different circumstances, I. E. , trying to stop at a train track, pulling a trailer, or going faster.

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.

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1999 Ford f150 brake failure do to brake lines rusted through.

1998 Ford f150 truck. Consumer states brake failure due to rusted out brake lines the consumer stated the brake lines should have been made out of stainless steel.

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.

Three brake lines rusted out and leaking in last 2 years incident date is an estimate.

Was stopping on highway, brake pedal went to floor. Vehicle stopped, upon inspection found rear brake line was rusted and leaking. I replaced the failed brake line.

The brake line from cab area to rear wheel on my 2003 Ford f150 corroded and emptied the master cyclinder of brake fluid. It is significant to note that no other brakelines or connections showed simiilar corrosion- more like you would expect on a 7 year old vehicle. It is my opinion that the corrosion is a materials problem and may be a reoccurring problem in other vehicle of this type. I also noted excessive scaling of the front wheel hubs and stearing arms of the same vehicle. This I believe is the result of inferior parts- I have never seen this level of deterioation of vehicle components like this. Whether this is a safety problem or not I don't know. Please accept this information as a couple of data points on this vehicle. I just felt it was necessary to advise NHTSA of the situation.

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The contact owns a 1997 Ford F-150. The contact stated that the spare tire cable, exhaust system manifold, fuel tank strap, brake line, bolts, erg valve, and the frame were rusted. The vehicle was not repaired. The manufacturer was made aware of the failure and denied to buy the vehicle back or provide any assistance. The failure mileage was 220,000 and the current mileage was 322,000.

Brake line to rear wheels corroded causing total loss of brake fluid and braking ability. Event occured backing out of driveway. Brake lines, fittings and fluid replaced.

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. .

My brakes failed on my 1999 Ford f150 that only has 102,000 miles on it. I was amazed to discover that the problem was due to a heavily corroded steel brake line. I am having a hard time understanding why the NHTSA doesn't require automobile manufacturers to use stainless steel for brake lines. After talking with a few mechanics, it seems that this type of failure is not uncommon in vehicles with 100,000+ miles on the odometer. I'm afraid to think what kind of accidents can occur with this type of premature brake failure.

The contact owns a 2005 Ford F-150. The brakes lock whenever he drives the vehicle. The brake pads, rotors and brake line were replaced. The repairs did not remedy the failure. The dealer nor the manufacturer have been contacted. The failure mileage 36,000.

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3 separate incidents of brake failure due to rotted/rusted brake lines. Luckily the incidents happened at low speeds and I was able to stop with the emergency brake. If I was going faster this could have had deadly consequences! since then, all brake lines have been replaced with stainless steel line at my own expense. Every problem that I have had with this truck (and there were many) can be traced back to catastrophic metal fatigue! there is no excuse for this manufacturers continued usage of substandard and/or poorly designed materials!!!!.

I went to drive my 1999 Ford F-150 last night, and the brake pedal went completely to the floor. No previous symptoms were evident. Upon inspection, it is evident the brake line along the frame to the rear wheels burst due to excessive corrosion. Further inspection showed that all of the other brake and fuel lines on the truck are electroplated, and maintain a silvery non corroded finish. However this line along the frame is obviously unplated, flaking chips of rusted steel, resulting in failure. Whether it was a design flaw, or manufacturing oversight, the unplated brake line could have had severe consequences.

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.

The contact owns a 1998 Ford f150. While idling at a traffic light with the brake pedal depressed, the vehicle began to roll until it crashed into another vehicle. No warning lights were illuminated. Aaa towed the vehicle and the brake lines were replaced. He has not notified the manufacturer. The contact has pictures of the defective brake lines. The current and failure mileages were 68,700. Updated 01-11-08. Updated 12/12/07.

The contact owns a 2000 Ford F-150. While driving 60 mph, the metal brake line to the rear brakes rusted through and began squirting brake fluid everywhere. The brakes extended to the floor when depressed and would not work properly. He was able to drive the vehicle home and repaired the brake line himself. The current mileage was 61,230 and failure mileage was 61,210. Updated 12/06/07.

Hydraulic brake failure. Vehicle towed to repair facility. Rear brake lines replaced due to corrosion.

The contact owns a 2006 Ford f150. Ever since the vehicle was purchased, it has been to the dealer on four occasions. The contact stated that his brakes feel spongy at all speeds and when idling. He stated that the brake pedal stops the vehicle, but it is not firm and extends all the way to the floorboard at any given moment. During one of the four trips to the dealer, the mechanic bled the brake line, but this did not resolve the failure. The contact received a letter from Ford in February of 2006, which stated that the vehicle failed to conform to both standard #105 and #135. The current mileage is 6,888 and failure mileage was 100.

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At 15,000 and 30,000 mile scheduled maintenances a brake hose inspected should be done. In our case it was completed and according to the dealership there were no found problems. However, when we were driving around a curve and there was a teenager on a four wheeler on our side of the road and we braked to avoid the child . . . We had no brakes on our 2005 F-150 supercrew. We were able to avoid injuries with our family inside the vehicle and the child we almost hit due to the brake failure. Upon towing the vehicle in they said that the brake hose into the intake was worn and blew off when we depressed the brake fast. I asked why this wasn't checked and they said because it was too hard to get to for a physical inspection during maintenance. The service tech also said he has seen this with several f150's. I see this as being a serious danger for these brake hoses to blow off and not be where they can be checked. We are paying for maintenance that is not being done not to mention peoples lives are at stake.

1999 Ford F-150 while on a short trip out of town I experience almost complete, sudden brake failure. Upon side of the road inspection, I found left rear brake line failed with brake fluid dripping on the pavement. Truck was taken to a local mechanic who said brake lines were rusted through. He replaced the broken left rear and the badly rusted right rear.

: the contact stated while driving 18 mph, the brakes failed. The vehicle was towed to the sales/service dealer, who determined the vacuum hose had come off. The manufacturer was notified. Updated 1/19/2007 -.

Pulling a 10 foot box trailer well within gvw limit. . . Main brake line failure, line along the frame rail appears to be rusted way beyond what would be expected for the vehicle year, brake line burst when brakes applied. . . Through inspection revealed all metal parts not aluminum are rusted, appears metal is inferior quality but factory. . . Lines to be replaced.

I have a 98 Ford f150 4x4 with 51000 miles on it. During routine maintenance I noticed that the front brake lines were swollen with rust where an outer rubber sleeve covers the steel to rubber connection. Upon inspection the line came apart. Rust was all that was keeping it together. I replaced the lines myself and I still have the old ones. It is obvious to me that the design is faulty; the outer sleeve retains moisture allowing the connection to rust away prematurely. My big concern is that I showed the problem to two different service advisors at two area Ford dealers and they didn't seem to care. I have tried to contact Ford by email twice and I don't get a response.

: the contact stated upon starting the vehicle in the morning, without any warning signal to indicate brake failure, the brake pedal was depressed and would not go all the way to the floor. The vehicle was towed to the dealership who determined a vacuum line had disconnected due to oil presence in the connection. The rubber hose was replaced. The contact denied any traces of oil in the surrounding of the vacuum hose connection. Updated 11/03/06.

: the contact stated while pulling out of the driveway at 3 mph, when the brakes were applied, the pedal went to the floor. An independent repair shop determined the brake line had rusted and exploded. Updated 10/4/2006 -.