NHTSA Complaint #11233762 — 2019 FORD F-450 SD

COMPLETE BRAKE SYSTEM FAILURE WITH ONLY 830 MILES ON THE VEHICLE. ON JULY 19, 2019 WHILE APPROACHING AN INTERSECTION ON E. CAUSEWAY APPROACH IN MANDEVILLE, LA. I APPLIED THE BRAKES TO STOP FOR A RED LIGHT, THE BRAKE PEDAL WENT TO THE FLOOR AND THE VEHICLE WAS NOT SLOWING ENOUGH TO AVOID HITTING THE VEHICLES AHEAD OF ME AT THE INTERSECTION. I RAPIDLY DOWN SHIFTED THROUGH THE GEARS TO REDUCE SPEED AND ALSO APPLIED THE PARKING BRAKE TO HELP REDUCE SPEED. WHILE THE VEHICLE DID SLOW DOWN IT WAS NOT ENOUGH TO AVOID HITTING THE TRAFFIC AHEAD, SO I VEERED OFF TO THE RIGHT AND MISSED THE OTHER CARS. AFTER SLOWING TO A ROLL I WAS ABLE TO PUT THE VEHICLE IN PARK TO BRING IT TO A COMPLETE STOP. ONCE I GATHERED MY THOUGHTS I WAS ABLE TO GET THE VEHICLE OFF THE MAIN ROADWAY AND CONTACT FORD ROADSIDE ASSISTANCE. TWO AND A HALF HOURS LATER A TOW TRUCK ARRIVED AND BROUGHT THE VEHICLE TO THE DEALERSHIP WHERE I HAD PURCHASED IT ONE WEEK EARLIER. WHILE WAITING FOR THE TOW TRUCK I INSPECTED THE VEHICLE AND FOUND A LARGE AMOUNT OF BRAKE FLUID SPRAYED IN THE ENGINE BAY BY THE MASTER CYLINDER AND RUNNING DOWN THE FRAME AND POOLING UNDER THE VEHICLE. I ALSO OBSERVED THAT THE FLARE NUTS AT THE MASTER CYLINDER HAD BEEN GALLED UP AND ALMOST ROUNDED AS IF A WRENCH HAD BEEN SLIPPING OFF DURING ASSEMBLY. THESE GALLED UP FLARE NUTS WERE ON THE LINES THAT APPEARED TO BE LOSING BRAKE FLUID.*DT *DT*JB CONSUMER STATED HE RECIEVED TRUCK BACK FROM DEALERSHIP. ISSUE ON FORD'S END DURING VEHICLE ASSEMBLY. LOOKS LIKE THE FACTORY HAS MISALIGNED ONE OF THE HARD BRAKE LINES AT THE MASTER CYLINDER. WHEN THEY TIGHTENED THE FLARE NUT THEY STRIPPED IT OUT IN THE MASTER CYLINDER HOUSING. THE LINE HAD ENOUGH FASTENING TENSION TO HOLD THE FLARE MATING SURFACES TOGETHER. APPARENTLY WHEN I APPLIED HARD BRAKING PRESSURE THE IMPROPERLY INSTALLED NUT ALLOWED THE BRAKE LINE TO SLIP BACK AND LOSE FLUID & PRESSURE CONTAINMENT. BRAKES WERE FINE.*JB