NHTSA Complaint #11475348 — 2021 FORD F-150

I was driving with my wife and our one month old baby on I-25 in Albuquerque on a hot day (truck screen indicated 106 F) when suddenly the AdvanceTrac traction control, forward pre-collision braking, adaptive cruise control, and ABS system warnings all came on the dashboard. At the same time the brake pedal went limp (no braking action for the first ~50% of the pedal press). I slowed the truck by coasting for over a mile and picked an off-ramp that I expected to be empty before getting off the highway. Upon exiting the highway, I pressed the brake pedal all the way down and at 90-95% of the pedal compression the brakes finally engaged but locked up the rear wheels leading us to skip and skid across two lanes. We were able to come to a stop in the middle of the ramp and then gently moved over to the side of the exit, again locking up the rear wheels when we came to a stop. Upon turning the truck off and turning it back on again everything went back to normal suggesting that it was some subsystem that caused the electronic brake booster and ABS to become unresponsive. After a week at the local Ford dealer, the service technicians were able to find the error code C05CF. This error code appears to be officially only triggered by "Brake Master Cylinder Piston Position Sensor "B" -This DTC sets due to incomplete or improper module programming procedures." Which suggests this problem may have been lingering for over 30k miles of use. Ford technicians updated the traction control module firmware, body control module firmware, and then reproduced the issue leading them to perform an ABS system calibration which they claim fixed the issue. It is claimed that no component replacement was necessary, only software updates and calibration. Full dealer notes attached as .pdf It's crazy to think a software bug caused our brake system to almost entirely fail on the highway, particularly with an error code that should only have been able to been generated at the factory.