Four problems related to brake disc caliper have been reported for the 2002 Ford F-250. The most recently reported issues are listed below.
On my Ford F-250 crew cab, all four brakes and rotors went bad and had to be replaced on 10-08-2009 with 81,125 miles on the vehicle. On 11-10-2009 (one month later) I had to replace a caliper on the left rear axle. On 5-16-2013 with 100030 miles (18,905 miles later) I had to install another new caliper and rotor on left rear axle and replace both brake pads. On 8-1-14 with 106,861 miles, (again with only 25,736 miles since last being replaced) both front calipers froze and ruined the left front rotor that will need to be replaced. All replacement parts used were genuine Ford parts. I bought the vehicle when it had approximately 54,000 miles so I don't know how many times the brakes were repaired prior to me buying it. From the internet I see that many others are having the same problems. These brake parts are unsatisfactory. Not only is it unsafe when they freeze from vibration, but it is extremely costly. I feel that this is a huge problem and a recall should be made. Thank you.
The contact owns a 2002 Ford f250. While driving 65 mph, the contact felt a vibration from underneath the vehicle. The steering wheel shook and the front driver side tire detached. The vehicle drove off the road, crashed into some trees, and caught fire. Both the driver and passenger were injured. A police report was filed. The contact stated that there was no blow out or loose treads that may have caused the failure. The insurance investigation concluded that the tire self-detached from the vehicle because the hub and caliper were defected. The failure may have also been due to heat fracture that caused the caliper to fail. After inspecting the vehicle, a mechanic suggested that the failure may have been caused by bad metal. The manufactured distributed a questionnaire, but the contact has not received a response from Ford. The vehicle and tire are in storage. The powertrain was unknown. The current and failure mileages were 100,000.
Since 300 miles I have taken the truck to the dealer every 3000 - 5000 miles for the rotors warping, shaking during stopping, severe pull to the right unexpectedly during stopping, no brakes when it is raining or wet out. I don't feel safe driving this truck, I have so far been able to keep from getting into an accident by driving off the road onto the berm until I could get it stopped. The dealers turn the rotors and lubricate the calipers(???) since when do you put grease or oil on the brake components? this works for about 3000 miles and back to shaky and no stop again. The dealer now tells me that it is out of warranty and will cost over $1000. 00 to fix. I pull a 30 foot camper mr Ford, would you like to be in front of me during an emergency stop? I would like you to be there.
Both front brake calipers continuously rattled. They sounded like they were loose and felt like they were going to fall off. The noise stopped if the brake pedal was tapped. The dealer installed new rotors and pads, however the noise persisted.