Summary
The Ford Super Duty has 12 recalls spanning 1988 through 2001, with the most serious recent issue affecting 2000 model year vehicles where a missing or improperly installed retaining clip can cause the brake pedal pushrod to disconnect, leaving the driver unable to apply the brakes at all.
The 2001 model year has a separate concern on Crew Cab configurations where the fuel filler pipe lacks a proper ground path through the outer fender. Filling the tank from an ungrounded hose or fuel can allows static electricity to build up and discharge, potentially igniting a fire. The 1999 model year carries three distinct issues: tie rod ends and drag link assemblies can have insufficiently hardened ball studs that wear prematurely and separate from their sockets, causing a loss of steering control; the accelerator cable core wire can fray against the conduit end fitting and prevent the throttle from returning to idle, leaving the vehicle accelerating uncontrolled; and on regular cab pickup configurations, the pickup box attachments can be damaged in a frontal impact and then shift or detach in a rollover, causing fuel to spill beyond acceptable limits. The 1999 model also has a compliance issue where French-language airbag warning labels were absent from the sun visors.
Going back further, the 1996 model year has undersized fasteners on the crossmember gussets that anchor the mid-ship fuel tank's rear strap, which can separate and reduce tank retention in a crash. On 1994 turbodiesel models using cruise control, the engine can continue accelerating for several seconds after cresting a hill when load suddenly drops. The 1993 model year has front bumper U-clips that can fracture, allowing the bumper to loosen and fall away so the vehicle rides over it. The 1992 and earlier range covers a 1990 concern on 7.5-liter engine models where the fuel return tube rubs against a body panel weld and eventually leaks fuel, and a 1989 issue on motorhome and commercial chassis where the brake and power steering return lines interact and apply light brake pressure without any pedal input. The 1988 model year has front axle track bar bracket bolts that loosen with use, producing steering shimmy that can worsen into damage to the steering linkage and eventual loss of steering control.
