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-250 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
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 12:00 pm 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. …
Tl 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.
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".
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. …
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. …
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. …
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.
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.
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. 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.
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.
Brake complaints in other F-250 SD years
Frequently asked questions
How common are brake problems on the 2002 Ford F-250 SD?
NHTSA has 30 complaints about the brakes of the 2002 Ford F-250 SD, 12% of the model year's 245 complaints. The component named most often is foundation components › disc › rotor (8 mentions).
Is there a recall for 2002 Ford F-250 SD brake problems?
No. NHTSA lists no brakes recall for the 2002 Ford F-250 SD, though it has 3 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-250 SD brake problems start?
Half of the complaints with a recorded mileage happened before about 49,000 miles, and 27% before 25,000 miles.
Is it dangerous?
Owners linked 4 crashes, 1 fire and 1 injury 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.