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 2005 Ford F-350 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
I have a 2005 Ford f350 4 wdr, super duty with v10, 4 sp. Auto, VIN no. [redacted]. I experienced sudden vehicle acceleration, ie. From a stopped position with vehicle in drive and foot on brake the vehicle, lunged forward, heavy braking would not stop vehicle it only caused acceleration. Only impact with mail box and snow bank stopped vehicle. I compared what had just happened with pressing on the accelerator and brake at the same time and this was different and did not result in loss of control.
Tl* the contact owns a Ford 2005 f-350 SD. The contact stated that the vehicle would make a loud squeaking noise whenever the brakes were applied, and she would also smell a burning odor. The vehicle was taken to an authorized dealer where the contact was informed that a brake caliper needed to be replaced. The vehicle was repaired, but the failure recurred. The manufactuer was made aware of the failure. The failure mileages were 18,413 and the current mileage was 38,156.
The brake failed to engage while coming down an incline at 5 MPH on a snow surface road with a trailer attached to the truck. This caused the truck to run into the trailer while coming down the incline. Dealer was notified.
Repeated brake caliper problems. Brake pads lock in on position while caliper releases. Result is that one brake pad in a set will quickly become worn while other pad is like new. Failure results when locked pad is undetected, then caliper, rotor and brake line damage result. This has occurred on 3 seperate instances and on seperate wheels. Ford has paid for one rear caliper, front rotors.this problem began on or before 16,000 miles. Vehicle has been serviced and repaired at Ford garages only. This vehicle is not a severe duty truck, has a tow haul package. Further: immediately, after one repair ABS lite came on and brakes went to floor. ABS stayed on for 10 minutes and then when brakes were pumped they went out and brake returned. Immediate thought was that ABS malfunction was due to brake repair and correct and that it was a temporary problem. …
Dt: the vehicle is a 2005 Ford f350. The brakes failed multiple times. Once when the consumer was driving she went to slow down at a traffic light and the vehicle would not stop. The consumer said that the only way she could keep from hitting another vehicle was to honk the horn. The vehicle has been in the dealership 10 times, and the dealership replaced the master cylinder 3 times. The consumer stated that since she has owned the vehicle it has been in the repair shop at least 25 days. The dealership has tried to assist her. She felt that there was some kind of problem with the electrical system. The problems occurred off and on. When she contacted the manufacturer, they gave her a hard time. They have not helped her at all. They told the dealer that they would not buy back the vehicle. …
I was backing loaded trailer down incline toward pond; "tow command" trailer brake controller did not work properly and the 2005 f-350 super duty truck, with wheels locked, was dragged backward toward the edge of the pond by weight of the trailer and its load; trailer and truck stopped before reaching edge of pond. This has occurred at other times, indicating that brake controller does not provide adequate braking in reverse at low speeds. The problem was reported to the selling dealer, who said their checks indicate the controller is working according to Ford specifications at the date of manufacturer in September, 2004, though a new version of the controller apparently has been installed on later models, beginning around March of 2006. …
While vehicle was parked in my driveway, level ground, pushed on brake pedal to put vehicle in gear. Brake pedal felt spongy, pushed on it again, bang, right to the floor. There the pedal stuck, up against the floorboard. Upon investigation, found that the portion of the master cylinder that the plunger bolts onto, broke away. The plunger bolts to the master cylinder in two places. Both bolt holes broke away from the casting. The casting looks faulty, no fresh break look to it at all. The vehicle has 43000 miles on it. Brakes have not been done yet, still roughly 50% pad wear. More of a daily driver unit, than a heavy puller. I'm just glad that I wasn't driving down the highway or pulling my holiday trailer, when this occured. Who knows what would have happened! I feel this is a major safety issue. Is it a rare case or are there other faulty master cylinders out there. …
I purchased a 2005 Ford f-350 super duty truck in July of 2005. On July 4 of this year I started to experience problems with the brakes hanging, causing the brakes to overheat and smell, also causing undo strain on the drive line on the truck. The problem has occurred several times and have returned to the dealer to have it fixed every time,(only to have it come back later on), one time at a dealer when I was out of state. That dealer stated that the Ford f250 next to mine in the shop had the same problem. My dealer has been in contact with Ford motor company about this, as I have been to, without satisfaction on what Ford is going to do. I feel this problem is now a safety issue.
I was slowing down to a stop light when my driverside rear tire was smoking profusely. I stopped to check the problem out and the rear brake was locked up. I spoke to workers at the Ford dealership and they told me this is a normal occurrence with this particular model truck. I replaced the driverside rear caliper and went on my way. Two weeks later the same thing happened to the passenger side rear caliper. The dealers I have spoken to once again said this is a normal occurrence and that you only get about a year out of the calipers. At over $250 a caliper this is very expensive. I don't tow with my vehicle or abuse it in any way. I am strict with maintaining it.
Rear brake drum failure - backer plate of my Ford f350 has corroded to the extent that the rear brake shoe retainer pins fell inwards and the back brake shoe twisted around grinding in the rear drum. Upon hearing a noise slowed and the rear wheel locked and spun the truck sideways on the road. This is a long wheel base,k crewcab pickup with an 8ft box. The disc rotor cover has also rusted through leaving a hole allowing small stones to jam between the rotor and brakes causing the vehicle to pull (ecentually start to brake on one wheel - problematic especially when braking on wet or icy roads.
Brake complaints in other F-350 SD years
Frequently asked questions
How common are brake problems on the 2005 Ford F-350 SD?
NHTSA has 23 complaints about the brakes of the 2005 Ford F-350 SD, 11% of the model year's 217 complaints. The component named most often is antilock/traction control/electronic limited slip (6 mentions).
Is there a recall for 2005 Ford F-350 SD brake problems?
No. NHTSA lists no brakes recall for the 2005 Ford F-350 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 2005 Ford F-350 SD brake problems start?
Half of the complaints with a recorded mileage happened before about 18,000 miles, and 62% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 1 fire 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.