Ford F-350 SD brake failure problems

Filed Feb 11, 2026 · Electrical · 94,000 miles · OK

The contact owns a 2022 Ford F-350 SD. While driving at an undisclosed speed and hauling a trailer, there was a delay with the trailer brakes before the trailer brakes engaged, causing the braking distance to be extended. Occasionally, the trailer brakes failed to engage, causing the electric brakes to activate and stop the vehicle. The contact became aware of the federal safety agency Campaign Number: 25V132000 (Electrical System) on the website, which referenced a similar failure. The dealer was made aware of the failure. The dealer informed the contact that the VIN was not included in the recall. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and confirmed that the VIN was not included in the recall. The manufacturer opened a case for the failure; however, no assistance was provided. The failure mileage was approximately 94,000.

Filed Jan 9, 2026 · Engine, Fuel system · CA · fire

Driving uphill at approx 20mph near my home. Loud bang/explosion from engine or front driver-side wheel well. Red alarm flashed on instrument cluster (something like “Front Brake Failure”) and strong odor of fuel or exhaust entered cab. I immediately pulled into a pullout and put vehicle in park when I noticed flames coming from the engine compartment through the gaps in hood and wheel well. I splashed a small amount of water on the driver side front tire, but the fire continued to grow. I backed away to a safe distance and called 911. Within 5 minutes, the entire engine compartment was on fire and I captured on video explosions as the fire raged Local fire department arrived within 15 minutes, but the entire engine and cab had already been destroyed by fire. Had I been driving at high speed or with passengers, this incident could have resulted in serious burn injuries and death. Had I been driving during summer months, this incident would have caused a devastating wildfire. Had I been in traffic, I may have caused a multi-car wreck. There were absolutely no warning indicators that such a violent incident could occur. Tow truck driver said it may have been a fuel filter issue which has caused other Super Duty’s to experience sudden and catastrophic engine compartment fires. Minimal research showed me that NHSTA is investigating Ford Super Duty for this very issue. My F350 is model year 2017. I also have video of fluids dripping from the burning vehicle and the droplets are on fire which leads me to believe that leaking fuel — possibly from a cracked plastic filter — may be to blame for this incredibly dangerous incident. The vehicles remains have been searched by California Highway Patrol and the remains are currently being investigated by State Farm Auto Insurance claims experts.

Filed Sep 23, 2025 · Brakes, Driver assistance · 1,000 miles · IL · crash · 2 injuries

The contact owns a 2023 Ford F-350 SD. The contact stated that the adaptive cruise control mode was inoperable. Additionally, the contact stated that while driving 50-55 MPH to the dealer, the contact noticed that the vehicle in front of the vehicle had stopped abruptly with no brake lights activated. The contact stated that upon depressing the brake pedal, the vehicle failed to respond. The contact attempted to veer to the left to avoid the other vehicle, but the passenger's side front end crashed into the rear of the other vehicle. There was no warning light illuminated. The contact stated that the six air bags of the vehicle deployed, and there was blinding smoke in the vehicle. The contact was transported to the hospital by ambulance and was hospitalized for 7 days. The contact was then transferred to a rehabilitation facility, where he was currently receiving care. The contact sustained a broken right hand and toe. The contact also sustained breathing complications as the contact's underlying cardiac and pulmonary health issues were triggered. The other driver sustained unknown injuries and was transported to the hospital by ambulance. Both vehicles sustained significant damage and could not be driven away from the scene. The contact's vehicle sustained front-end fender and hood damage and other unknown damage. The vehicle was towed to the collision repair shop for an estimate of the damage. A police report was filed. The dealer was notified of the brake failure and informed the contact that the VIN was not included in a related recall. The manufacturer was not notified of the failure. The failure mileage was 1,000.

Filed Jun 16, 2025 · Electrical · 14,000 miles · WV

The contact owns a 2024 Ford F-350 SD. The contact stated that while driving at various speeds and hauling a trailer, the trailer brakes failed to activate while depressing the brake pedal. During the failure, there were no warning lights or messages displayed. The cause of the failure was not yet determined. The manufacturer and local dealer were notified of the failure, but no assistance was provided. The failure mileage was 14,000.

Filed May 23, 2025 · Electrical · 102,195 miles · UT

The contact owns a 2022 Ford F-350 SD. The contact stated that while depressing the brake pedal, the trailer brakes failed to assist with slowing the vehicle. The message that the trailer was disconnected was displayed on the instrument panel. The vehicle was taken to the dealer however, the vehicle was not diagnosed. The vehicle was not repaired. The contact became aware of the federal safety agency Campaign Number: 22V193000 (Electrical System); however, the VIN was not included. The manufacturer was informed of the failure and confirmed that the VIN was not included in the federal safety agency Campaign Number: 22V193000 (Electrical System). The manufacturer opened a case regarding the failure. The manufacturer referred the contact to the federal safety agency Hotline to report the failure. The failure mileage was 102,195.

Filed Jan 14, 2025 · Brakes, Fuel system · 37,000 miles · NY

The contact owns a 2021 Ford F-350. The contact received notification of the federal safety agency Campaign Number: 24V957000 (Fuel System, Diesel); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact stated that while depressing the accelerator pedal after stopping, the vehicle was slow to respond. The contact stated that there was several minutes before the vehicle responded as needed. The contact stated that the failure occurred after coming to a full stop. The contact stated there was no warning light illuminated. Additionally, the contact stated that while towing a loaded trailer, the vehicle was losing traction, and the rear end was swaying to the right and to the left. The contact had not taken the vehicle to a dealer to be diagnosed or repaired. The contact stated that during the failure there were several unknown warning lights illuminated. The contact stated that 3 months after purchasing the vehicle, the vehicle experienced brakes failure. The contact had taken the vehicle to an independent mechanic who diagnosed the vehicle and determined that all four brake pads and calipers needed to be replaced. The vehicle was repaired; however, the contact stated that the failure recurred while depressing the brake pedal, with an abnormal metal-on-metal sound coming from the brakes. The contact stated that the brakes were independently slowing the vehicle. The failure mileage was approximately 37,000. VIN tool confirms parts not available.

Filed Jul 26, 2024 · Brakes, Driver assistance · 100 miles · GA

The contact owns a 2022 Ford F-350 SD. The contact stated that while hauling a trailer, the brakes failed to operate as needed. The vehicle was taken to the local dealer, who updated and replaced the Auxiliary Power Interface Module (APIM) several times. The vehicle was repaired, but the failure recurred. Additionally, the radio turned on without driver interaction. The contact stated that the Forward Collision Avoidance system and the mirrors were turning on and off, the crash alert was engaged, and the brake was applied without driver input. The steering wheel was vibrating. The manufacturer was contacted and declined a buyback of the vehicle. The failure mileage was approximately 100.

Filed Aug 23, 2023 · Brakes · OH

Lost all Brake pressure, the Pedal went to the floor while driving. This could have lead to a serious injury or death while driving.

Filed May 23, 2023 · Brakes, Electrical · CA

The vehicle has a Gross Combined Weight Rating (GCWR) of 30,000 LBS. While towing, the vehicle would show on the dash at intermittent times "Trailer not connected." When this occurs, the trailer brakes are no longer operating placing all braking on the tow vehicle with the potential for brake fade or complete brake failure and catastrophic loss. This intermittent failure of the electrical brake system does not occur on other tow vehicles that were equipped with after-market brake controllers, such as Tekonsha. The vehicle was brought into the Ford Dealership to look into the issue. Ford had the truck for nearly two weeks and could not figure out the problem. After much self-research, it was determined that the factory installed brake controller cannot discriminate between trailers using electric brakes and trailers using electric/hydraulic brakes. The fix is to install an actuator (ETrailer Code DX35FR - Adapter Module for BrakeRite Electric Over Hydraulic Actuator - OE Ford, GM Brake Controllers) on the trailer to provide resistance that will allow the factory installed controller to recognize the trailer/hydraulic brakes. A technician also advised that a work around would be to wire in small magnets to the wiring of the trailer to provide the resistance. The forums state that this occurs with trailers five years or older for which there are thousands on the road. This limitation/defect applies to the majority of trailers being towed on the highways today. Failure to advise drivers of this limitation/defect and the intermittent sequencing of the disconnection leaves non-professional, recreational drivers at significant risk of brake failure while towing up to nearly 30,000 pounds. the federal safety agency should investigate why standard after-market brake controllers have no issues of this kind while the "supposedly" state-of-the-art new vehicle controllers are limited. It is my understanding that this same issue is found with GM and possibly RAM products.

Filed May 8, 2023 · Electrical · CT

While driving the trailer plug melted at the connection to the truck. I got a message that the trailer was disconnected and there were no brakes on the trailer. The plug on the truck is burned.