1996 Ford F-350 Problems

What owners report

Owners of this model year most often describe tire tread separation and cracking on the 16-inch tires these trucks came with, and brake problems including rusted-through rear brake lines and pedal going to the floor. These are older, high-mileage trucks (median around 103,000 miles), so many complaints reflect wear and corrosion rather than new failures, and several describe issues years after purchase.

1. 1
   Tires

   Tire tread separation and sidewall cracking

   • 22 complaints (17%)
   • median 35,846 mi at 8.6 yrs old (3 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2000–2011

   Complaints describe tread peeling off or blowing out on 16-inch tires, often at highway speeds, with body and fender damage and, in a few cases, loss of control. Several owners note sidewall cracks or separation found on tires with relatively low miles, and say tire dealers declined to help. A few report the spare tire near the exhaust heat shield catching fire while towing. Reported at a wide range of mileages, from roughly 30,000 miles up to about 100,000, mostly during highway driving.

   Recall 96V161000

   What to check: Inspect all tires, including the spare, for sidewall cracks and tread separation, and check the date codes. Verify the correct rear inflation pressures against the certification label, since a recall addressed incorrect label information.

   2 excerpts from owner complaints in NHTSA records

   “I was driving on hwy 10 at 63-65mph when the tread separated, wrapped around my rear axel, bent brake cable, tore fender skirts, bent fender supports, chipped paint, bent fender, trim pieces. Tire steel belts only surface to drive on, making truck inoperable. Did not turn over, but had I been on my usual route through mountain curves, would have gone over the side of the mountain. Concern that 16 inch tires are not being looked at. Do not feel safe. Firestone blaming Ford explorer. My vehicle not a Ford explorer. It is a tire defect. …”

   NHTSA complaint #747041, filed 2001-06

   “I was travelling eastbound on route 2 in connecticut when my drivers side rear tire fell apart. The tread separated from the tire body. I understand that this is not one of the tires listed on recent news reports, however, the exact same thing happened to my tire as the ones seen on news reports. I contacted a local firestone dealer in enfield, connecticut who stated to me that the a/t tire was not in question and therefore there was nothing he could do. I reitterated to him that this is the same problem that has been seen on news reports. …”

   NHTSA complaint #727100, filed 2000-08
2. 2
   Brakes

   Rear brake line corrosion and brake failure

   • 19 complaints (15%)
   • median 91,773 mi at 7.9 yrs old (3 state mileage, few)
   • 3 mention a crash, fire or injury
   • filed 1996–2007

   Owners describe the brake pedal going to the floor with little warning, often after the truck sat or during towing, and finding brake fluid leaking from a rear brake line that had rusted through. Some report repeated failures at the tubing, fittings, and master cylinder, with dealers replacing lines and fittings. Others describe dragging rear brakes, vibration, or uneven brake work after service. Mostly reported between about 75,000 and 175,000 miles, often on trucks that sit for periods between use.

   What to check: Have the brake lines, especially the long rear line, inspected for rust and pitting, and check for fluid weeping at the fittings and master cylinder. Ask when the fluid was last changed.

   2 excerpts from owner complaints in NHTSA records

   “Stepped on brake to release the parking brake and the brake peddle went to the floor, causing me to hit a post. On investigation I found the brake line to the rear wheels rotted in the middle. All other lines in the area are like new. I have owned much older vehicles without having brake line problems. I believe the material in these lines are quite inferior and dangerous for a vehicle. I had just been towing my fifth-wheel trailer the day before.”

   NHTSA complaint #10023563, filed 2003-06, 76,000 miles

   “1/07 squeak in front left wheel, took to sears as brakes/bearings under warranty. Ended up w/ complete brake job front & rear. Picked up vehicle, poor pedal pressure, no e-brake. Took back to sears they adjusted. In april had rear brakes fail to stop vehicle while pulling horse trailer. Only front brakes engaged. Took back couldn't find a problem. Took to another shop they found only pads replaced on rt rear not on left. …”

   NHTSA complaint #10198472, filed 2007-08, 174,400 miles
3. 3
   Vehicle speed control

   Speed control switch overheating and engine fires

   • 11 complaints (8%)
   • median 108,500 mi at 9.8 yrs old (6 state mileage, few)
   • 7 mention a crash, fire or injury
   • filed 1998–2009

   Complaints describe smoke or fire from the engine compartment, often while the truck was parked and shut off, traced to the speed control deactivation switch at the master cylinder. Other owners report cruise control stopping working, or burnt wiring at the switch, with the part replaced at their expense. Several note their vehicle was not included in the related speed control recall. Reported from around 60,000 to 200,000 miles, in trucks of varying age, often while parked.

   Recall 06V286000

   What to check: Ask whether the speed control deactivation switch has been replaced or the recall performed, and look at the switch and wiring at the master cylinder for burnt or melted plastic.

   2 excerpts from owner complaints in NHTSA records

   “On 1/30/09 I experienced a fire in the engine compartment on my Ford F-350 due to a faulty speed control deactivation switch. I just happened to walk out to the vehicle that was parked in my driveway, not running, to see a glow underneath the truck. I opened the hood and realized that there was a fire coming from the brake master cylinder. After extinguishing the fire, and burning my hands, I could see that the reservoir was melted and the speed control deactivation switch is where the fire was coming from.”

   NHTSA complaint #10257267, filed 2009-02, 202,000 miles

   “Cruise control recall list does not include the Ford f350 truck. My cruise control quit working during a routine service at 60,000 miles. Service personnel at bobby jones Ford, augusta, georgia, had apparently disconnected the cruise control because of a fluid leak from the switch. After complaining, this vehicle had other switch failures (turn signal and ignition switches) these switches were replaced at my expense, also the cruise control switch was also replaced at this time (at my expense of $20.88 part and $40.00 labor). …”

   NHTSA complaint #10139081, filed 2005-10, 60,000 miles
4. 4
   Engine cooling

   Engine stalls from camshaft position sensor failure

   • 6 complaints (5%)
   • median 123,447 mi at 12.0 yrs old (5 state mileage, few)
   • filed 2001–2012

   Owners of 7.3L diesel trucks describe the engine running rough for a few seconds and shutting off while driving or after starting, sometimes leaving no power steering or brakes. Complaints commonly attribute the stall to the camshaft position sensor and describe replacement at a dealer or shop, in some cases more than once. Several owners note their truck was not covered by a related recall for the same sensor. Typically reported from around 50,000 to 200,000 miles, on 7.3L diesel trucks.

   What to check: Ask whether the camshaft position sensor has been replaced and keep a spare, since owners describe repeat failures. On a test drive, watch for rough running or a sudden shutdown.

   2 excerpts from owner complaints in NHTSA records

   “The existing recall 07v-553 (camshaft position sensor on Ford 1997-2003 f-super duty, e-series, and excursion vehicles with 7.3l diesel engines) seems to be incorrectly narrow in scope. I have a 1996 F-350 with the same 7.3l diesel engine noted in the recall, and had the exact failure described in this recall. I had it repaired at a Ford dealership on sept 21, 2007, and can provide complete documented information from that repair. Why did Ford not include f-series trucks that use the 7.3l engine (such as the F-350) in this recall? …”

   NHTSA complaint #10220361, filed 2008-03, 123,447 miles

   “I had the cmp sensor (cam position sensor, f6tz-12k073-a) replaced at 83,733 miles and again at 88,500 miles. The engine runs rough for 3 seconds and dies. It will crank but not restart. Vehicle was towed to mechanic and cmp sensor was replaced.”

   NHTSA complaint #10234058, filed 2008-07, 88,500 miles
5. 5
   Fuel system

   Fuel leaks from tank, lines, and filter fittings

   • 5 complaints (4%)
   • median 102,000 mi at 15.6 yrs old (2 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2000–2012

   Complaints describe diesel or gasoline smells, drips or running leaks under the truck, and in some cases dual fuel tanks leaking. Owners report leaks traced to the fuel filter/water separator drain valve, fuel pump, pressure regulator housing, and injector seals, with dealers sometimes noting the part is a frequent failure or on back order. A few describe stalling or reduced power linked to clogged fuel filters and pickup screens. Reported from about 47,000 miles upward, on both diesel and gasoline trucks.

   Recall 96V146000

   What to check: Look under the truck and around the fuel filter housing and tanks for dampness or staining, and check for a fuel smell in the cab. Ask whether fuel filter and tank components have been serviced.

   2 excerpts from owner complaints in NHTSA records

   “I have a Ford F-350 7.3l turbo diesel. While driving on the freeway at 70 MPH., the check engine light came on and the engine power was reduced by half. After I pulled over the light went out and the engine returned to normal. Two weeks later the same thing happened again. I took it to a mechanic who found the fuel filter, the fuel pump, and the fuel pickup screens clogged with residue from the liner of the fuel tanks.”

   NHTSA complaint #10466835, filed 2012-07, 157,000 miles

   “1. Began smelling diesel fuel in cab. Then noticed drips on driveway. 2. Went to sawgrass Ford on date below where I was told this is the fuel filter/water separator drain valve, and it is happening frequently and part is on back-order. They saw leak is almost a stream especially with engine running. 3. Two weeks and no call from dealer.”

   NHTSA complaint #10314841, filed 2010-02, 47,000 miles

Buying note. On a truck this old, condition and service history matter more than the model year: have the brake lines, tires, fuel system, and speed control switch checked before buying. Ask for records of sensor, brake, and fuel-system repairs, and treat corrosion as the main thing to inspect.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.