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 2002 Ford F-150 owners, lightly cleaned up (personal details are redacted by NHTSA).
The recall ie an inline fuse on speed control deactivation switch did not work it just caught on fire and ruined my master cylinder and brake system.it wont hold brake fluid now because the switch melted into it.Ford says oh well recalls been done
Tl* the contact owns a 2002 Ford f-150. The contact stated that flames were emitting from the engine compartment. The vehicle was taken to the dealer who diagnosed that the brake switch melted, causing damage to the master cylinder. As a result, the master cylinder assembly needed to be replaced as well as the wiring harness and a brake repair kit. The manufacturer was made aware of the failure who advised the contact that they would contact her at a later date. The vehicle was not repaired. The failure and the current mileage was 106,673.
Tl* the contact owns a 2002 Ford f-150. While driving 55 MPH, the cruise control failed to operate and the cross control went into a locked position. The contact attempted to brake, but the vehicle would not stop. The contact placed the vehicle in neutral and was able to slow down the vehicle. When the vehicle finally stopped, the contact disconnected the cruise control cable. The vehicle was not diagnosed or repaired. The dealer and manufacturer were not made aware of the failure. The failure mileage was 222,112.
Tl* the contact owns a 2002 Ford f-150. While driving at 65 MPH, the accelerator pedal became stuck and the brakes became inoperable. The contact was able to regain control of the vehicle. The failure occurred twice. The vehicle was taken to an authorized dealer, but was not diagnosed or repaired. The manufacturer was notified. The approximate failure mileage was 140,000. ...updated 07-08-15
Tl* the contact owns a 2002 Ford f-150. The contact stated that the vehicle caught fire while parked. The fire originated at the brake booster area and spread to the interior of the vehicle. The fire department extinguished the flames. The vehicle was destroyed. The manufacturer was notified. The failure mileage was 193,000. Updated 9/18/14 updated 2/3/2015
(1) without warning the brake light came on due to a failure of a hydraulic control unit, which would have ultimately lead to a failure of the ABS system if it weren't for the awareness of the driver. The failure of the ABS could have lead to an even greater catastrophe than just the cost of parts and labor. (2) it is my understanding through my research and the word of the service department at bozeman Ford dealership in bozeman, montana that this particular problem is not unheard of. In fact, it has become enough of a problem that Ford has made an attempt to correct the problem, by replacing the old hydraulic control unit with another hydraulic control unit, in addition to an electronic control unit and a bracket that mounts the two together. Although Ford has made an attempt to resolve the problem, they have not made any strides in issuing a recall for the faulty hcu. …
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. …
Front brake caliper mounting bracket seized on the slide bolts that allow the brakes to move in and out when pressed and released. The slide bolts that allow the caliper to move have seized causing the vehicle to pull very hard to one side of the road. In my case I was towing a 20' commercial landscape trailer equipped with dual axle trailer brakes. I approached a traffic light and proceeded to make a left turn going a speed of approximately 15 to 20 MPH when I pressed the brake during the turn the truck pulled extremely hard to the left resulting in my trailer jack knifing into the left side of the truck causing major damage to my bed and rear wheel on my truck. …
Tl contact owns a 2002 Ford f150. The vehicle was repaired according to NHTSA campaign id number 05V388000 (vehicle speed control). A harness was installed, but it did not remedy the harness and vehicle speed control switch failures because there was no leak at the time. Currently, brake fluid is leaking around the switch from the master cylinder and the cruise control. The dealer and manufacturer stated that they previously repaired the cruise control switch, but the contact disagrees. The dealer agrees that it needs to be repaired currently; however, the contact would be responsible for the expenses. The failure mileage was 140,000.
Tl 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.
Brake complaints in other F-150 years
Frequently asked questions
How common are brake problems on the 2002 Ford F-150?
NHTSA has 42 complaints about the brakes of the 2002 Ford F-150, 5% of the model year's 821 complaints. The component named most often is pedals and linkages (4 mentions).
Is there a recall for 2002 Ford F-150 brake problems?
No. NHTSA lists no brakes recall for the 2002 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 2002 Ford F-150 brake problems start?
Half of the complaints with a recorded mileage happened before about 74,000 miles, and 17% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 5 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.