2002 FORD F-250 SD Service Brakes, Hydraulic Problems

2002 FORD F-250 SUPER DUTY COMPLETE BRAKE FAILURE, RESULTED IN ACCIDENT. FAILURE CAUSED BY FAULTY BOOSTER PUMP AND MASTER CYLINDER ISSUES. FORD DENIES ANY ISSUES WITH SAID COMPONENTS, A QUICK SEARCH ON THE NET RESULTS IN HUNDREDS OF SIMILAR OCCURRENCES. $1400 IN PARTS TO REPAIR. INSURANCE WOULD NOT COVER "MECHANICAL PARTS". *TR

Mileage: 70,831

MAIN BRAKE LINE RUSTED THROUGH. CATASTROPHIC LOSS OF ALL BRAKING POWER TO ALL WHEELS. SAILED THROUGH A SEVEN LANE INTERSECTION. POOR QUALITY MATERIALS USED THAT LEAD TO BRAKE LINE RUSTING. SHOULD HAVE USED STAINLESS STEEL TO PREVENT RUST. FORD DENIED PRODUCT LIABILITY CLAIM AS "OUT OF WARRANTY". CLASS ACTION LAWSUIT SHOULD RE-PLUMB ALL BRAKE LINES TO BE STAINLESS STEEL. WILL NEVER ADVISE PEOPLE TO BUY FORD TRUCKS. *TR

Mileage: 91,000

VEHICLE WAS ONE MONTH OLD WHEN STEERING WHEL SHOOK WHEN BRAKES APPLIED. VEHICLE NOW HAS 49,000 MILES AND AGAIN THE SAME PROBLEM. BOTH TIMES ROTORS HAD TO BE TURNED AND PAD REPLACED. *TR

Mileage: 49,000

I EXPERIENCED A LEAK IN THE POWER STEERING HOSE FROM THE POWERSTEERING PUMP TO THE HYDRABOOST ON MY 2002 FORD F250 WHILE DRIVING IN THE MOUNTAINS PULLING A 30FT. 5TH WHEEL TRAILER. I HAD TO USE 1 GALLON OF FLUID TO RETURN 90 MILES. ACCORDING TO ANOTHER MECHANIC, THIS IS A COMMON FAILURE AND IS DUE TO POOR DESIGN AND ENGINEERING THIS HOSE IS CARRIED BY THE LOCAL DEALER AND THEY INDICATED THAT IT HAS A HIGH FAILURE RATE. THIS FAILURE RESULTS IN LOSS OF POWERSTEERING AND POWER BRAKES. *TR

Mileage: 53,251

TL*THE CONTACT OWNS A 2002 FORD F250 SUPER DUTY. WHILE BACKING THE VEHICLE OUT OF THE DRIVEWAY AT APPROXIMATELY 5 MPH, THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. THE VEHICLE DID NOT STOP. THE EMERGENCY BRAKE WAS APPLIED, BUT THE VEHICLE STILL WOULD NOT STOP. THE TRAILER THAT WAS BEING PULLED WHIPPED AROUND AND STRUCK THE SIDE OF THE VEHICLE, WHICH CAUSED MAJOR DAMAGE TO THE TRUCK AND THE TRAILER. THE CURRENT MILEAGE WAS 71,000 AND FAILURE MILEAGE WAS 70,000.

Mileage: 70,000

BRAKE ISSUE- HAVE HAD DISK'S ON THE FRONT SURFACED ONCE IN 20K MILES AND IS IN NEED TO RESURFACE AGAIN. I HAVE A 3/4 TON PICKUP, DIESEL AND FEEL THE ROTORS ARE NOT VENTED TO REDUCE THE (HEAT) BUILD UP SUFFICIENTLY. I FEEL THIS IS A ENGINEERING PROBLEM THAT SHOULD BE REMEDIED. WILL WIND UP IN BRAKE FAILURE. *TR

Mileage: 20,000

PICKUP IS A DIESEL F250, 2002, EXTENDED CAB. BRAKES OVERHEAT TOO EASILY AND ROTORS BECOME WARPED. WHEN RUNNING DOWN HILL AND HOLD BRAKES FOR EXTENDED PERIOD IT BECOMES NEARLY IMPOSSIBLE TO MAINTAIN CONTROL OF THE VEHICLE. PICKUP IS DESIGNED TO CARRY LOADS, AND TOW TRAILERS, BUT THIS OCCURS WITH VIRTUALLY NO LOAD. IT IS APPARENT THAT THE SAME BRAKES ARE USED ON LIGHTER WEIGHT PICKUPS (I.E. GASOLINE ENGINE F250'S) AND THE DIESEL VERSION SHOULD HAVE HEAVIER BRAKES. I HAVE NOTED THAT FORD RECOGNIZES THE PROBLEM IN THAT THEY HAVE BEEN INSTALLING MUCH LARGER BRAKE ROTORS ON THEIR NEWER DIESEL PICKUPS. I HAVE HAD TO PURCHASE AFTERMARKET BRAKES TO INCREASE THE COOLING ABILITY TO MINIMIZE THIS PROBLEM. FIRST TIME BRAKES WERE REPLACED WITH FORD ROTORS AND SAME PROBLEM OCCURRED ALMOST IMMEDIATELY. DATE, NUMBER OF FAILURES, ETC. LISTED BELOW ARE MISLEADING AS THIS IS A PROBLEM EVERY TIME I BRAKE. FORD SERVICE PERSONS AND PARTS PERSONS JUST SHRUG THEIR SHOULDERS AT ME WHEN I COMPLAIN!!! *TR

RE: 2002 F250 5.4L S/D S/C THE SAME SPEED CONTROL SWITCH FAILURE DUE TO NORMAL BRAKE USAGE AS WARNED ONLINE AND IN FORD'S RECALL. I NEVER RECEIVED A LETTER FOR THE RECALL, I DISCOVERED THE INFORMATION ONLINE. WHY IS FORD ONLY PUTTING A BAND-AID ON THIS PROBLEM? WHY ARE THEY NOT FIXING THE SWITCH OR THE MASTER CYLINDER TO SOLVE THIS PROBLEM? COST, I'M SURE. SAD. *NM

Mileage: 85,000

MY 2002 F250 4X4 SUPER DUTY HAS THE TYPICAL FRONT END SIDE TO SIDE SHUDDER WHEN BRAKES ARE APPLIED. I BOUGHT THIS TRUCK IN ALASKA SHIPPED IT TO MONTANA, AND NOTICED THE SHUDDER, TOOK IT TO HELENA MT. FORD DEALER AND THEY REPLACED THE FRONT CALIPERS AND ROTORS. SAME PROBLEM. I SUSPECT THE BALL JOINTS ARE DEFECTIVE, OR THE ROTORS ARE NOT DESIGNED FOR THE WEIGHT OF THE VEHICLE. I AM SURE AS THESE GET OLDER SOMETHING WILL FAIL FOR SOMEONE AND A LAW SUIT WILL ENSUE.THIS SEEMS TO BE AN ONGOING PROBLEM. *NM

Mileage: 500

PRIOR TO THE ACCIDENT WE HAD THE TELESCOPING BRAKE AND GAS PEDAL REPLACED FOR A DEFECT. (IT DIDN'T WORK) ON SEPTEMBER 9TH 2005 AT APPROX 12:00PM OUR FORD EXCURSION SUDDENLY ACCELERATED, WHICH RESULTED IN LOSS OF CONTROL OF THE VEHICLE AT SPEEDS IN EXCESS OF 80 MPH. AVOIDED ROLL OVER AND HITTING OTHER VEHICLES. SPUN OUT 2 TIMES BEFORE CRASHING INTO A FENCE @ MCAS (MARINE CORPS AIR STATION) YUMA ARIZONA. WAS TAKEN TO THE HOSPITAL BY AMBULANCE. HIGHWAY PATROL. ACCIDENT INVESTIGATOR AND YUMA POLICE HAVE PICTURES AND REPORTS OF THE ACCELERATION PEDAL STILL MASHED INTO THE SUV'S FLOOR-BOARD STILL OPEN AT FULL THROTTLE WITH ENGINE OFF. THE ACCIDENT REPORT STATES MECHANICAL DEFECT OF ACCELERATION PEDAL. THE TIRES AND UNDER CHASSIS CAUGHT WERE ON FIRE WHEN VEHICLE CAME TO A CRASH STOP OR IT COULD HAVE BEEN A FIRE PRIOR THE INVESTIGATOR WASN'T SURE. WHEN THE VEHICLE WAS PUT IN PARK THE TIRES WERE STILL SPINNING OUT AS IF THE SUV WAS IN A DRIVE GEAR. ALTHOUGH I SUFFERED MINOR INJURED PULLED NECK AND BACK MUSCLES AND BROKEN ELBOW (RADIAL NECK FRACTURE). I COULD HAVE BEEN KILLED OR SERIOUSLY INJURED OR KILLED ANOTHER HUMAN DUE TO THIS DEFECT. COMPLETELY TERRIFIED TO EVER DRIVE AGAIN. *JB

Mileage: 38,000

BRAKES AND STEERING WHEEL SHAKE WHEN THE BRAKES ARE APPLIED. CONSUMER WAS INFORMED BY DEALER THAT NEW BRAKES AND ROTORS WERE NEEDED. *AK

BRAKES AND STEERING WHEEL SHAKE WHEN THE BRAKES ARE APPLIED. CONSUMER WAS INFORMED BY DEALER THAT NEW BRAKES AND ROTORS WERE NEEDED. *AK

NO ACCIDENT. 2002 FORD F250 4X4 SHORT BED CREW. BRAKE ROTOR WARPING ALL THE TIME. NOT DRIVING THROUGH WATER WHILE HOT! *AK

Mileage: 5,000

THE POWER STEERING FLUID WAS LEAKING FROM UNDERNEATH THE VEHICLE WHILE PARKED. THE VEHICLE WAS TOWED TO THE DEALER, WHO INFORMED THE CONSUMER THAT THE METAL LINE THAT WENT TO THE POWER STEERING PUMP AND TO THE BRAKING ASSIST MOTOR ERUPTED, AND NEEDED TO BE REPLACED. *AK THERE WAS BRAKE PULSATION, THE ACCELERATOR PEDAL WAS FAULTY, THE STEERING WAS HARD TO TURN DURING NORMAL MANEUVERS, WHEN THE 4 X 4 WAS HIGH OFF THE ROAD, THE WHEEL TURNED AND LOCKED TO THE STOPPER, LUNGED, AND THE REAR WHEELS SPUN AROUND. *SC

Mileage: 26,872

WHILE APPLYING THE BRAKES AT ANY SPEED VEHICLES SHOOK. CONSUMER WAS ABLE TO MAINTAIN CONTROL OF THE VEHICLE. CONSUMER TOOK VEHICLE TO THE DEALER FOR INSPECTION, AND MECHANIC DETERMINED THAT THE ROTORS NEEDED TO BE REPLACED, AND REPLACED THEM FOUR TIMES. HOWEVER, PROBLEM RECURRED. *AK

VEHICLE HAD PROBLEMS WITH THE BRAKES. THE BRAKE ROTORS WARPED EVERY 20,000 MILES. IT WAS ALSO DISCOVERED THAT THE BALL JOINTS WERE LOOSE WHEN THE VEHICLE WAS BEING REPAIRED. PROVIDE FURTHER DETAILS. *JB MECHANIC ALSO FOUND THAT LOWER BALL JOINTS WHERE LOOSE. *LA

Mileage: 43,000

WHEN DRIVING ON ICY OR SNOWY ROADS THE ABS ENGAGED, IT STAYED RELEASED FOR 3-4 SECONDS. THIS RESULTED IN THE VEHICLE FREE WHEELING. AS A RESULT, THE VEHICLE REAR ENDED ANOTHER VEHICLE. THE DEALERSHIP INDICATED THAT THE ABS WERE WORKING NORMAL. *AK THE ABS RELEASED ITSELF. THE CONSUMER REQUESTED REIMBURSEMENT. *SC *JB

UNABLE TO STOP IN A REASONABLE DISTANCE. WHILE APPLYING BRAKES AND STEADILY APPLYING MORE PRESSURE TO INCREASE RATE OF DECENT, I GET A HARD PEDAL THAT YOU CAN'T PUSH ANY HARDER EVEN WITH BOTH FEET. BRAKES WILL NOT APPLY ENOUGH PRESSURE TO ACTIVATE THE ABS EVEN ON WET PAVEMENT, ONLY ON GRAVEL OR SNOW. I HAVE PAPERWORK FROM FORD STATING THEY HAVE HAD A NUMBER OF COMPLAINTS AND ARE "AWARE OF THE SAFTEY CONCERN" BUT ARE "UNABLE TO FIX." FORDS TECK LINE ADVISED TECHNITION TO "REPLACE PARTS UNTILL CONCERN IS FIXED." I'VE BEEN TO 4 DEALERS. THEY HAVE REPLACED THE POWERBOOSTER AND PUT AFTERMARKET PADS ON THE FRONT WITH NO EFFECT. WHEN I INQUIRED ABOUT THE LEMMON LAW AFTER SEVERAL RETURN TRIPS TO THE DEALER, THEY NOW SAY IT'S A "PERCIEVED PROBLEM", AND PRINT ON THE PAPERWORK "NO CONCERNS NOTICED." AT THE LAST TRIP TO THE DEALER THE TECH. SAID HE "SAW WHAT I WAS TALKING ABOUT AND TEST DROVE A NEW TRUCK TO COMPARE BUT SAID IT WAS THE SAME WAY. THAT MEANS TO ME THAT THEY ARE STILL BUILDING THESE TRUCKS EVEN THOUGH THEY'VE FAILED TO FIX THE PROBLEM. I FIRST RETURNED THE TRUCK WITH 3000 MILES. I NOW HAVE 36,000 AND STILL NO BRAKES. I'M AFRAID TO DRIVE IT WITH A LOAD. SOMEONE FROM NHSTA OR SOMEONE INDEPENDENT OF FORD NEEDS TO TEST DRIVE THIS TRUCK. PLEASE RESPOND. FORD REFUSES TO DO ANYTHING.*AK

Mileage: 3,000

BRAKE ROTORS AND PADS WERE REPLACED EVERY 20,000 MILES. THE LAST TIME THAT VEHICLE WAS REPAIRED ROTORS, PADS AND CALIPERS WERE REPLACED. DEALER CLAIMED THERE WAS NOTHING WRONG WITH THE VEHICLE. *AK CONSUMER PURCHASED VEHICLE NEW, AND AT 23,000 MILES CONSUMER EXPERIENCED VIBRATION ON STEERING WHEEL WHEN APPLYING BRAKES. VEHICLE CURRENTLY IS AT 43,000 MILES AND STILL POSSES THE SAME PROBLEM. *LA

Mileage: 20,000

BRAKE ROTORS AND PADS WERE REPLACED EVERY 20,000 MILES. THE LAST TIME THAT VEHICLE WAS REPAIRED ROTORS, PADS AND CALIPERS WERE REPLACED. DEALER CLAIMED THERE WAS NOTHING WRONG WITH THE VEHICLE. *AK CONSUMER PURCHASED VEHICLE NEW, AND AT 23,000 MILES CONSUMER EXPERIENCED VIBRATION ON STEERING WHEEL WHEN APPLYING BRAKES. VEHICLE CURRENTLY IS AT 43,000 MILES AND STILL POSSES THE SAME PROBLEM. *LA

Mileage: 20,000

STEERING INOPERATIVE WHEN PRESSING DOWN HARD ON BRAKE PEDAL. FORD SAYS THIS IS A NORMAL CONDITION AND HAVE NO FIX. 2002 FORD F-250 WITH 7.3 DIESEL ENGINE.*AK

WARPING OF FRONT BRAKE ROTORS. TRUCK HAS NOT PULLED ANYTHING HEAVY OR CARRIED A HEAVY LOAD. PULLING TO THE LEFT, AND FRONT END SHAKING DURING NORMAL BRAKING. SYMPTOMS INCREASE WITH BRAKING PRESSURE. ONLY 25,000 MILES ON TRUCK. THE DEALER CHARGED FOR REPAIRS AND WOULD NOT COVER ROTOR UNDER WARRANTY.

Mileage: 25,499

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. *JB

Mileage: 300

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. *JB THE DEALER INSTALLED NEW ROTORS AND PADS, HOWEVER THE NOISE PERSISTED. *NM

Mileage: 35,000

MY VEHICLE HAS 34000 MILES, IT'S A F250SD 4X4 DIESEL. WHEN BRAKING THE FRONT END SHAKES. THIS HAS BEEN ATTRIBUTED TO ROTOR WARP. DEPENDING ON THE MECHANIC I HAVE BETWEEN 70-90% OF THE BRAKE PADS LEFT. THE VEHICLE DOESN'T NORMALLY TOW OR CARRY A GREAT DEAL OF WEIGHT. I THINK THAT THERE IS A PROBLEM WITH THE ROTORS OR SOME MECHANICAL PROBLEM THAT CAUSES ROTOR WARP SO QUICKLY. *JB

BRAKE LOOSE POWER RESULTING IN PEDAL FADE AND HARD BRAKING .THE VEHICLE CAN EXPERIENCE EXTENDED STOPPING DISTANCE, ALSO HAVE CHANGE PAD TWICE AND ROTOR ONE TIME BY THE DEALER AND PROBLEM STILL REOCURRING. PLEASE PROVIDE FURTHER INFORMATION. TS

WHEN APPLYING THE BRAKES HARD AS IN NEAR EMERGENCY BAKING THE STEERING SYSTEM BECOMES INOPERABLE. SOMETIMES IT FEELS AS IF POWER STEERING IS LOST, OTHER TIMES IT FEELS AS IF THE STEERING LOCKS UP. I FEEL THIS IS A FATAL DESIGN FLAW AND GOES TOTALLY AGAINST ALL INFORMATION THAT THE USE OF ANTI LOCK BRAKES SHOULD BE A "STOMP-STAY-AND STEER" PROCESS. I NO LONGER FEEL SAFE DRIVING THIS TRUCK IN HEAVY TRAFFIC. *AK