Summary
The Ford F-Series has 10 recalls covering 1985 through 1997 model years, with the most serious recent issue being a 1997 brake booster pushrod retainer pin that may be missing or improperly installed, causing complete loss of braking with no warning before a potential crash.
The final years of this production run also saw a 1993 engine recall where interference between the accelerator lever and the automatic transmission modulator lever on F600 models can prevent the engine from returning to idle after releasing the accelerator pedal. A similar throttle issue affects 1992 F600 models, where accelerator return springs can fatigue and fail under engine vibration, also leaving the engine unable to drop to idle when the pedal is released. On 1994 models, two separate issues exist: Super Cab trucks with an optional power front seat can develop a short circuit where seat cushion support wires chafe through the lumbar motor wiring harness, and certain models under 8,500 lb. GVWR may have been built with non-functional airbag diagnostic modules, meaning the airbag system and its warning light would not work in a crash.
Going back to the early 1990s, 1990 models with dual fuel tanks have a check valve that can fail and transfer fuel between tanks until one overflows past the filler cap, creating a fire risk in the presence of any ignition source. The 1989 model year has a transmission park gear snap ring that can fracture and let the park gear slide off the output shaft, preventing the transmission from locking in park and allowing the vehicle to roll away.
Earlier production carries several fuel-related fire risks: 1986 models have a short nylon jumper tube on the left frame rail that can develop pinholes and leak fuel, and 1985 models with fuel-injected engines use spring-lock fuel line couplings that can disengage during normal use and release fuel with fire potential. The 1988 model year has a glazing compliance issue affecting the windshield or glass.
