2002 Ford F-250 Sd Brakes Problems

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. *TR

NHTSA ID

10618258

Incident

Oct 8, 2009

Mileage

81,125 mi

TL* THE CONTACT OWNS A 2002 FORD F-250 SD. THE CONTACT STATED THAT WHILE STOPPED, HE DEPRESSED THE BRAKE PEDAL AND THE PEDAL ABNORMALLY TRAVELED TO THE FLOORBOARD ACCOMPANIED BY A LOUD POP. THE CONTACT INSPECTED THE VEHICLE AND NOTICED BRAKE FLUID LEAKING. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 66,000. *TR

NHTSA ID

10523291

Incident

Jul 5, 2013

Mileage

66,000 mi

TL* THE CONTACT OWNS A 2002 FORD F-250 SD. THE CONTACT STATED THAT WHILE EXITING A RESIDENTIAL DRIVEWAY, THE CONTACT NOTICED THAT BRAKE FLUID HAD LEAKED ONTO THE FLOORBOARD. THE CONTACT INSPECTED THE VEHICLE AND DISCOVERED THAT THE FRAME EXHIBITED CORROSION. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR AN INSPECTION. THE FAILURE WAS NOT REPORTED TO THE MANUFACTURER. THE FAILURE AND CURRENT MILEAGE WAS 74,000.

NHTSA ID

10521501

Incident

Jun 22, 2013

Mileage

74,000 mi

TL* THE CONTACT OWNS A 2002 FORD F250 SD. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, THE BRAKE PEDAL TRAVELED RAPIDLY TO FLOOR UPON ENGAGING. THE VEHICLE FAILED TO SLOW DOWN UNTIL AFTER REPEATED PRESSURE WAS APPLIED TO THE BRAKE PEDAL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THE BRAKE LINES FRACTURED DUE TO CORROSION. THE VEHICLE WAS REPAIRED. IN ADDITION, THE ENTIRE UNDER CARRIAGE WAS COMPLETELY RUSTED BEYOND REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 60,000.

NHTSA ID

10512342

Incident

Jul 11, 2012

Mileage

60,000 mi

ON THIS DATE IN 2010 MY F250 SD HAD THE LEFT TIE ROD REPLACED ALONG WITH A COMPLETE "HEAVY DUTY" FRONT WHEEL BRAKE SERVICE (INCLUDING ROTOR REPLACEMENT) AND A FOUR WHEEL ALIGNMENT PERFORMED BY A FORD DEALERSHIP. THIS WAS TO ADDRESS A SEVERE SHIMMY AND VIBRATION THAT OCCURRED WHENEVER THE BRAKES WERE APPLIED. I'D CONSIDER THE CONDITION TO BE SO SEVERE THAT IT WAS A SAFETY CONCERN ON MAINTAINING CONTROL OF THE VEHICLE AT TIMES. TODAY, 5/22/12 AT 112,800 MILES AND LESS THAN TWO YEARS AFTER THE INITIAL REPAIR I AM EXPERIENCING THE EXACT SAME SYMPTOMS AGAIN. I'VE DONE SOME RESEARCH ON-LINE AND HAVE FOUND MULTIPLE CONSUMER COMPLAINTS OF THIS VEHICLE FROM MODEL YEARS 2000 - 2003 WITH THIS COMPLAINT. OWNERS ARE HAVING MULTIPLE OCCURRENCES OF HAVING TO REPLACE THE ROTORS AT A FREQUENCY OF 10K - 20K MILES. I'M TAKING MY TRUCK TO THE DEALER IN THE MORNING FOR HIS INSPECTION. WITH MY PERSONAL EXPERIENCE AND THE NUMBER OF COMPLAINTS I'VE SEEN IN MY RESEARCH I FIND IT HARD TO BELIEVE THAT FORD IS NOT SUPPORTING ANY CORRECTIVE ACTION. *TT

NHTSA ID

10459239

Incident

Jul 5, 2010

Mileage

93,106 mi

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

NHTSA ID

10339422

Incident

Jul 12, 2008

Mileage

70,831 mi

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

NHTSA ID

10327558

Incident

Feb 25, 2009

Mileage

91,000 mi

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

NHTSA ID

10275460

Incident

Jun 26, 2009

Mileage

49,000 mi

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

NHTSA ID

10242803

Incident

Sep 8, 2008

Mileage

53,251 mi

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.

NHTSA ID

10236648

Incident

Jul 12, 2008

Mileage

70,000 mi

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

NHTSA ID

10231434

Incident

Sep 18, 2004

Mileage

20,000 mi

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

NHTSA ID

10211055

Incident

Dec 6, 2007

MY 2002 FORD F-250 SUPER DUTY TRUCK CAUGHT FIRE DUE TO THE BRAKE SWITCH RECALL PROBLEM. THE BRAKE SWITCH (UNDER THE HOOD) BURNED AND THE FUSE BLOCK (UNDER THE DASH) MELTED. THE CAB FILLED WITH SMOKE WHILE MY SPOUSE WAS DRIVING. THE SWITCH, FUSE BLOCK, AND CABLE END WERE REPLACED DUE TO THIS INCIDENT. *TR

NHTSA ID

10199416

Incident

Jun 13, 2007

Mileage

96,000 mi

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

NHTSA ID

10171913

Incident

Oct 24, 2006

Mileage

85,000 mi

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

NHTSA ID

10152732

Incident

Jan 1, 2003

Mileage

500 mi

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

NHTSA ID

10136086

Incident

Sep 9, 2005

Mileage

38,000 mi

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

NHTSA ID

10103331

Incident

Oct 8, 2004

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

NHTSA ID

10102173

Incident

Nov 30, 2004

Mileage

5,000 mi

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

NHTSA ID

10099274

Incident

Oct 27, 2004

Mileage

26,872 mi

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

NHTSA ID

10072265

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

NHTSA ID

10065228

Incident

Mar 2, 2004

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

NHTSA ID

10064775

Mileage

43,000 mi

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

NHTSA ID

10066014

Incident

Dec 12, 2001

Mileage

3,000 mi

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

NHTSA ID

10062889

Incident

Mar 10, 2004

Mileage

20,000 mi

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

NHTSA ID

10062486

Incident

Mar 17, 2004