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-350 owners, lightly cleaned up (personal details are redacted by NHTSA).
Stepped on brake to release the parking brake and the brake peddle went to the floor, causing me to hit a post. On investigation I found the brake line to the rear wheels rotted in the middle. All other lines in the area are like new. I have owned much older vehicles without having brake line problems. I believe the material in these lines are quite inferior and dangerous for a vehicle. I had just been towing my fifth-wheel trailer the day before.
On a rainy day, rear brake lining grabbed actuating the ABS system. As I have found, this problem is discussed in Ford TSB 9805a24a. The brake pedal fell as additional pressure was needed to stop. Described as "normal" in special service message 03731. (a nice way to describe a problem that you do not want to fix.) the ABS brakes stopped pumping. The system then appeared as though no brakes were applied. The truck was not slowing down. Either the back brakes and possibly the front were not functioning at all, or all 4 wheel were locked up and the truck was sliding. (tires were all in good condition.) I was forced to put the truck into a ditch in order to avoid the vehicle in front of me. Later testing on a wet surface revealed that I would have been better off to pump the brakes, something that manufacturers of ABS systems advise you not to do. …
1/07 squeak in front left wheel, took to sears as brakes/bearings under warranty. Ended up w/ complete brake job front & rear. Picked up vehicle, poor pedal pressure, no e-brake. Took back to sears they adjusted. In April had rear brakes fail to stop vehicle while pulling horse trailer. Only front brakes engaged. Took back couldn't find a problem. Took to another shop they found only pads replaced on rt rear not on left. They did complete brake job on rear (new drums and pads) took in 2 weeks later still not correct and had vibration when braking. Ended up with re-surface of front rotors and new pads. 7/29/07 pulling horse trailer rear ended vehicle on 19th ave in sf due to rear brakes not engaging at all. Only fronts engaged. Rear brakes not working at all.
Dt: the contact complained about a brake problem. The brake fluid caused corrosion on the brake fittings. On August 7, 2003 the front brakes failed while the vehicle was going up hill. The Ford dealer replaced the tubing and fittings. On May 24, 2004 the rear brakes failed while he in a parking lot. Again the Ford dealer replaced the tubing and fittings. On November 1, 2005 the master cylinder experienced corrosion at the brake fittings, causing the brakes to fail. There was brake fluid pouring out of the front driver side wheel. Another dealership drained the brake system and replaced the line. The problem has not recurred. Updated 11/29/2004 -
While driving, going down grade, towing a trailer, driver's front brakes caught fire due to brake caliper piston failure, experienced spongey, travel to floor and no brakes, hit elk, dlr can't correct.
Drove this truck over 1000 miles this trip and parked it for 2 weeks. Then to travel a short distance brake pedal went to the floor first time to apply brakes.found brake fluid running off frame, and had mechanic inspect for problem.found brake line that goes to the rear brakes was rotted the full length front to rear. All other lines(fuel,etc) in the same area were in good condition.new line was installed..
While traveling normal highway speeds, dual wheel brakes overheat, causing rear wheels to drag, brakes fade when hot, driver has had to put vehicle in reverse and back to release brakes, drums and shoes have been replaced 2 times, vehicle has been in shop five times, this is an intermittent problem.
Motorhome eldorado 29 1/2 ft. 12000 gvw, ABS failure: pedal goes to within an inch of floor, can't pump brake, brake action seems inadequate in stopping on dry pavement or gravel, only rear wheels stop vehicle, not enough brake pressure during panic stop.
ABS: while coming to intersection, pumped brakes, rearended/ locked up , caused accident, vehicle hit passenager's side of another vehicle.
Vehicle has ABS brakes. On wet type pavement vehicle fails to stop when ABS brakes are applied. Dealers have not corrected problem. Owner is very concerned for safety.
Brake complaints in other F-350 years
Frequently asked questions
How common are brake problems on the 1996 Ford F-350?
NHTSA has 28 complaints about the brakes of the 1996 Ford F-350, 22% of the model year's 130 complaints. The component named most often is antilock/traction control/electronic limited slip (10 mentions).
Is there a recall for 1996 Ford F-350 brake problems?
No. NHTSA lists no brakes recall for the 1996 Ford F-350, 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 1996 Ford F-350 brake problems start?
Half of the complaints with a recorded mileage happened before about 92,000 miles.
Is it dangerous?
Owners linked 3 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.