Which parts fail
Components named in complaints (service brakes, ABS, rotors and pads, parking brake).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Ford F-150 owners, lightly cleaned up (personal details are redacted by NHTSA).
The brake fluid pressure sensor is leaking on to the electrical main computer wires its also leaking from the electrical harness coming from the brake fluid pressure sensor causing the brake tail lights to fail intermittently during vehicle operation
Tl* the contact owns a 1996 Ford f-150. The contact was notified by his mother that the vehicle was on fire while parked in the driveway. The contact noticed flames under the hood on the driver's side near the windshield. The contact was able to extinguish the fire. When the contact opened the hood, he noticed that the wiring harness, fuse box, and relay box were burned, and the master brake cylinder was completely melted. The contact referenced NHTSA campaign number: 05V017000 (vehicle speed control). The fire department was not notified. There were no injuries and a police report was not filed. The vehicle was not taken to a dealer. The manufacturer was not made aware of the failure. The approximate failure mileage was 200,000.
Dt*: the contact stated the vehicle was parked at an independent repair shop for inspection of the brakes due to a previous failure of the master cylinder and brake fluid leakage, when a fire erupted from the front under hood area and spread from the vehicle to the repair shop. No injuries were sustained. Extensive damage was sustained to the vehicle and the repair shop. A police report was not taken. The fire department was alerted and extinguished the fire. The fire department inspected the vehicle and determined the fire originated from the master cylinder. The vehicle was awaiting further inspection by a manufacturer representative. There was a NHTSA recall, #05V388000, regarding the vehicle speed control. The vehicle was not included in the recall due to the VIN. Updated 9/15/2006 -
While driving ABS and brake warning light came on stopped to check problem and saw fire. Had to replace master cylander and some wiring. 3 other people, including mother in laws van have had problem.
Dt: on June 22, 2005 the consumer's Ford f 150 began smoking under the hood while parked and turned off. The vehicle had been sitting for about 9 hours. The cruise control switch located on top of the master cylinder shorted out and looked like it was getting ready to catch on fire. The short melted the plastic reservior that holds the brake fluid to the point where it almost burned through. The owner removed the electrical connector to stop the burning. That connector was the cruise control switch. The part cooled off and the owners taped up the connector so it would not make any connection with any metal parts. The owners states that the vehicle was taken in to the Ford dealership because the check engine light would come on. This had been a problem for about a year. The dealership would turn off the light off and tell the owner that the vehicle checked out alright on their computer. …
I have previously submitted a complaint odi id number 10110013 dated 8-3-05. At this time, I will insist that a serious consideration be given to the wiring harness connected to the cruise control servo whereby- the horn is in play there!!! I am of course talking about recall #05V388000 (NHTSA recall campaign number) Ford f150 /SUV '95- '01 with cruise control fire potential. The fuse (#13 as listed in the manual - check out the number of items connected to that one fuse!) had blown before a fire destroyed my whole truck. That is to say I had sustained damage to my vehicle. Ford service -mccafferty of langhorne, pa recently installed the inline bandaid at the mfg. Request. Mccafferty again left me to there streets with an obviously burned harness/cruise servo pin connections. (with the harness disconnected there is no horn! Can I stress this enough? …
Copy of email to Ford: I wrote to you a couple of months ago regarding an extreme level of corrosion occurring on my 1996 f150 which resulted in the oil pan rusting through only to be rebuffed. Well now the level of corrosion is even worse. The brake lines are so corroded that one of them burst and nearly caused an accident. Clearly this is not normal. This vehicle is only used for personal use and is only used on the highway for transportation. I have another vehicle, a Jeep, which sits next to it that is 5 years older that is not exhibiting the corrosion found under your vehicle. As I mentioned in my previous letter, I am the original owner and the vehicle s mileage is less than 60K. Clearly this vehicle is defective but your earlierresponse to me indicates that you don t care. …
Total break failure, with no warning. Ford dealership (sterling Ford) reported right side front breakline had rusted through allowing break fluid to drain. Recommended replacement of all front breaklines and flex lines on both right and left side. Cost $355. Concern is way didn't the rear breaks system provide some margin of breaking capacity. Why did both systems fail simulataneously?
Vehicle has been returned to dealer four times since purchased new. The right front brake catches when brakes are applied, causing the right front brakes to skid on road surface. This has been especially dangerous during winter conditions and has caused the vehicle to go into an unwanted skid, with loss of control.
Dt: the contact states when it was damp or raining the brakes locked. The problem was intermittent, but has become constant. The vehicle was taken to the dealership, and they stated all Ford trucks were made that way. There have been no corrections to the vehicle at this time.
Brake complaints in other F-150 years
Frequently asked questions
How common are brake problems on the 1996 Ford F-150?
NHTSA has 34 complaints about the brakes of the 1996 Ford F-150, 10% of the model year's 324 complaints. The component named most often is antilock/traction control/electronic limited slip (15 mentions).
Is there a recall for 1996 Ford F-150 brake problems?
No. NHTSA lists no brakes recall for the 1996 Ford F-150, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 1996 Ford F-150 brake problems start?
Half of the complaints with a recorded mileage happened before about 150,000 miles.
Is it dangerous?
Owners linked 1 crash, 4 fires and 0 injuries to brakes problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.