2003 Ford Expedition SERVICE BRAKES, HYDRAULIC

TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 45 MPH, THE BRAKE PEDAL DROPPED TO THE FLOOR AND THE CONTACT EXPERIENCED A LOSS OF BRAKING CAPABILITY. THE CONTACT STATED HE CRASHED INTO A TREE STUMP AND SNOW ON THE GROUND AND THE VEHICLE CAME TO A STOP. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE APPROXIMATE FAILURE MILEAGE WAS 18,535. UPDATED 3/14/11 *CN IT WAS DETERMINED THE MASTER CYLINDER WAS LEAKING FLUID AND ULTIMATELY FAILED. UPDATED 05/04/11

BRAKE LINES RUSTED AND LEAKED CAUSING SUDDEN LOSS OF MOST BRAKING. I BOUGHT THIS FORD NEW IN JULY OF 2003. AFTER THE BRAKE FAILURE, THE VEHICLE WAS TOWED. I HAD ALL BRAKE LINES REPLACED, AND STILL HAVE THE PIECE WHICH LEAKED. THE SHOP SAID IT IS BECAUSE THE BRAKE LINES ARE ROUTED ON TOP OF THE FRAME RAILS, AND SALT BUILDS UP. BUT I'VE LIVED IN THIS AREA ALL MY LIFE (I'M 66) AND HAD MANY OLDER OR HIGHER MILEAGE VEHICLES, BUT NEVER HAD THIS HAPPEN BEFORE. I UNDERSTAND THAT YOU ARE INVESTIGATING CHEVY BRAKE LINE FAILURE, AND THINK YOU SHOULD INCLUDE FORDS. *TR

TL*THE CONTACT OWNS A 2003 FORD EXPEDITION EDDIE BAUER. UPON STARTING THE VEHICLE HE ATTEMPTED TO SHIFT IT OUT OF PARK AND THE BRAKE PEDAL DEPRESSED TO THE FLOOR. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHERE HE WAS INFORMED THE BRAKE LINES FOR THE FRONT BRAKES WERE RUSTED THROUGH. THOSE BRAKE LINES WERE REPAIRED. THE FAILURE HAS NOT RECURRED SINCE BUT HE EXAMINED HIS VEHICLE AND NOTICED THE BRAKE LINES FOR THE REAR BRAKES WERE VERY RUSTY. THE VEHICLE WAS NOT TAKEN TO BE EXAMINED AND HAS NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 58,900. THE VIN WAS UNAVAILABLE.

MY 2003 FORD EXPEDITION HAD A SUDDEN BRAKE FAILURE WHILE MY SEVENTEEN YEAR OLD DAUGHTER WAS DRIVING. LUCKILY SHE WAS NOT HURT WHEN THIS INCIDENT TOOK PLACE. I FOUND THE BRAKE RESERVOIR TO BE COMPLETELY EMPTY AND REFILLED IT IMMEDIATELY. THEN I DISCOVERED THE REAL PROBLEM. THE REAR FACTORY BRAKE LINES WERE CONSTANTLY RUBBING AGAINST THE REAR SPRINGS OF THE CAR , THUS WEARING A HOLE IN THE BRAKE LINE. THIS RESULTED IN RAPID LOSS OF BRAKE FLUID , WHICH ALSO LED TO SUDDEN BRAKE FAILURE. THIS WOULD OBVIOUSLY BE A MANUFACTURERS DEFECT AND I CANT IMAGINE WHY SOMEONE AT FORD DIDN'T SEE SUCH AN OBVIOUS PROBLEM. *TR

MY BRAKES BEGAN TO SQUEAL AROUND 50K. THIS IS THE FIRST BRAKE SERVICING REQUIRED ON THIS VEHICLE. I WAS TOLD BY A NUMBER OF MECHANICS THAT THE FRONT ROTORS NEEDED TO BE REPLACED BECAUSE THEY WERE WORN DOWN TOO MUCH. I WAS SURPRISED ABOUT THIS AND FOUND THAT THIS IS A VERY WELL KNOWN AND COMMON PROBLEM WITH THE 2003 FORD EXPEDITIONS. APPARENTLY, THESE ROTORS ARE NOT "DEFECTIVE" IN MATERIAL OR WORKMANSHIP OTHERWISE THERE WOULD BE A RECALL. THIS IS A PRIME EXAMPLE OF POOR DESIGN AND ENGINEERING. IT IS COMPLETELY RIDICULOUS TO EXPECT ANYONE TO BELIEVE IT IS NORMAL TO REPLACE BRAKE ROTORS ON EACH BRAKE PAD CHANGE. I HAVE BOUGHT AMERICAN MADE VEHICLES MY ENTIRE LIFE. I WAS ALWAYS TOLD THAT THE FOREIGN CARS WERE JUNK AND COST A LOT OF MONEY TO MAINTAIN. OVER THE YEARS I HAVE SPENT MUCH MONEY AND TIME REPAIRING MY AMERICAN MADE CARS. I HAD BOUGHT THE CHEAPEST CAR I COULD FIND BACK IN 2000. A HYUNDAI ELANTRA. I HAVE HAD ZERO PROBLEMS. NOT A SINGLE ONE. THE MILEAGE IS OVER 100K AND I HAVEN'T EVEN NEEDED TO CHANGE THE BRAKE PADS. THIS CAR WAS THE ABSOLUTE CHEAPEST CAR I COULD FIND ON THE MARKET IN 2000. I WILL TAKE THIS AS AN ILLUSTRATION OF HOW POORLY THE FORD LINE OF PRODUCTS ARE EITHER DESIGNED OR BACKED UP BY THE MANUFACTURER. *JB

THE ROTORS HAVE BEEN CONSTANTLY WARPING. THE ROTORS WERE MACHINED AT 24985, 35498 AND 40520 MILES. THE DEALERSHIP TOLD ME THIS WILL BE THE LAST TIME THE ROTORS CAN BE TURNED AND NEW ROTORS WILL HAVE TO BE PURCHASED IF/WHEN THEY WARPED AGAIN. DOES NOT SEEM NORMAL FOR THE ROTORS TO BE TURNED EVERY 5000 TO 10000 MILES. 8JB

DT: 2003 FORD EXPEDITION. THE CONSUMER STATED THE ROTORS CREATED A HUGE SAFETY HAZARD . THE BRAKES WERE MADE OF HARD METAL, AND THE ROTORS WERE MADE OF SOFT METAL WHICH WORE THEM DOWN. THERE WERE NO BRAKE PROBLEMS PRIOR TO FINDING THIS DEFECT. THE VEHICLE HAS 50,000 MILES ON IT, AND WAS TAKEN TO DEALER FOR REGULAR MAINTENANCE TO THE BRAKES. THE DEALERSHIP REFUSED TO LET THE CONSUMER TAKE THE VEHICLE UNTIL THE ROTORS WERE REPLACED. THEY HAD NEVER BEEN TURNED. THE ROTORS WERE REPLACED. THE ROTORS WERE WORE OUT BELOW SPECIFICATION. THIS HAPPENED A MONTH AGO. THE CONSUMER CONTACTED FORD, AND THEY CONTACTED THE DEALERSHIP. A REGIONAL DIRECTOR WAS TO INSPECT THE PROBLEM. THEY DID NOT CONTACT THE CONSUMER, HE CALLED THEM, AND THEY TOLD HIM HIS CLAIM WAS DENIED.*AK

FRONT BRAKE ROTORS COMPLETELY WORN DOWN AFTER ONLY 23,000 MILES. SEEMS TO BE A CHRONIC PROBLEM WITH THIS YEAR/MODEL.

2003 FORD EXPEDITION DEVELOPED PROBLEMS WITH THE BRAKE EQUIPMENT.***NO ANSWER REQUIRED***. *MR THE FRONT BRAKE ROTORS WERE COMPLETELY WORN DOWN. *SC

2003 FORD EXPEDITION EXPERIENCING PROBLEMS WITH THE BRAKE EQUIPMENT. *MR THERE WERE SIGNIFICANT ESCALATING PROBLEMS WITH THE BRAKES INCLUDING DUSTING, DIFFICULTY STOPPING PARTICULARLY FROM HIGHER SPEEDS AND CHATTER SOUNDS. THE PROBLEM WAS SAID TO BE DUE TO OVERHEATING OF THE ORIGINAL PADS. THE PROBLEM WAS SO BAD THAT THE ROTORS WERE WELDED TO THE RIMS. THE CONSUMER REQUESTED REIMBURSEMENT. *SC

FORD EXPEDITION 2003 FRONT BRAKES AND BRAKE SYSTEM FAILED. *BF THE CONSUMER STATED THERE WAS VISIBLE DUSTING, DIFFICULTY STOPPING AND BRAKE CHATTER. THE CONSUMER WAS TOLD THE PROBLEM WAS DUE TO INCREDIBLY HIGH AND OVERHEATING FROM THE ORIGINAL BRAKE PADS, THE PROBLEM WAS SO BAD THAT THE ROTORS WELDED TO THE RIMS. *JB

FRONT ROTORS WORE OUT PREMATURELY WITH LESS THEN 25,000 MILES ON THE VEHICLE. FRONT ROTORS WERE REPLACED THREE TIMES BY THE DEALER. *AK

THE DEALERSHIP REPLACED THE FRONT AND REAR PADS AT 14,000 MILES, AND RESURFACED THE ROTORS. AT 23,000 MILES WHEN CONSUMER APPLIED APPLIED THE BRAKES, THEY PULSATED. DEALER INDICATED TO THE CONSUMER THAT FRONT ROTORS NEEDED TO BE REPLACED.*AK THE DEALER REPLACED THE BRAKE FLUID BECAUSE IT WAS BURNT. THE CONSUMER SUSPECTED THERE WAS PRESSURE ON THE BRAKE PADS PROBABLY FROM THE ABS. *JB

VEHICLE WAS TAKEN TO THE DEALER FOR A ROUTINE INSPECTION, AND MECHANIC DETERMINED THAT THE BRAKE PADS AND ROTORS NEEDED TO BE REPLACED DUE WORN OUT PARTS. *AK THE BRAKE PADS REDUCED BRAKE ROTOR THICKNESS BELOW MINIMUM SAFE THICKNESS FOR NEW PADS. THE AVERAGE BRAKE PAD LIFE WAS 12K TO 81K MILES. IF THEY ARE NON FORD PADS, ROTOR FAILURE WOULD OCCUR IN AS LITTLE AS 3K MILES. THE CONSUMER REQUESTED A WRITTEN AGREEMENT TO REFUNDED THE MONIES PAID FOR THIS DEFECT AND TO COVER ALL FUTURE COSTS OF ABNORMAL REPLACEMENTS. *SC *JB

WHILE DRIVING CONSUMER APPLIED THE BRAKES AND PEDAL WENT TO THE FLOOR. ABS BRAKING LIGHT APPEARED ON THE DASHBOARD AND REMAINED ON. CONSUMER WAS ABLE TO DRIVE THE VEHICLE TO THE DEALER FOR INSPECTION, AND MECHANIC DETERMINE DTHAT THE ABS BRAKE MODULE NEEDED TO BE REPLACED.

EXCESSIVE BRAKE DUST ACCUMULATION SINCE NEW. ROTORS HAVE BEEN TURNED ONCE AND NOW NEED TO BE REPLACED WITH PADS AT 23,600 MILES. *AK

CONSUMER STATED BRAKE LINE WORE OUT PREMATURELY, AND EXCESSIVE BRAKE DUST WAS PRODUCED. *AK

2003 FORD EXPEDITION WITH AROUND 17000 MILES. BRAKES ARE NOT RIDDEN. FRONT BRAKE PADS WORE OUT. FROM THE DEALERSHIP (MOSSY FORD, SAN DIEGO), "FORD HAS REDESIGNED THE BRAKE PADS AND WE NEED TO REPLACE ALL FOUR PADS." I ASKED IF THERE WAS A DESIGN FLAW WITH USING LOW QUALITY PADS ON THE ORIGINAL EQUIPMMENT. I ASKED IF THIS HAS BEEN SEEN BEFORE. NO ANSWER WAS GIVEN. I WOULD LIKE TO KNOW IF THIS IS A REPEATING THEME. IT SOUNDS PRETTY SUSPICIOUS.*AK

BRAKE SYSTEM WAS DEFECTIVE, WHICH CAUSED THE BRAKE PADS TO WEAR OUT PREMATURELY. MANUFACTURER HAD AN UPDATE KIT THAT COST $233.00 PLUS LABOR. THE UPDATE KIT HAS A DIFFERENT BRAKE PAD MATERIAL THEN THE ONE FROM THE FACTORY. THE FACTORY BRAKE PAD WORE THROUGH THE ROTORS EXTREMELY FAST AND DAMAGED THE ROTORS.*AK

EXCESSIVE WEARING OF ROTORS AND PADS. FRONT (RIGHT & LEFT) BRAKE PADS NEEDED TO REPLACED AS WELL AS ROTORS AT 25,000 MILES. CAR IS NOT DRIVEN HARD. FORD SERVICE CENTER(MAGUIRE'S FORD OF HERSHEY, PA) STATED THAT THERE WAS STILL PADDING LEFT AND THAT THERE WAS NO METAL CONTACT WITH ROTORS, BUT THE ROTORS WERE WORN TO 1.1 ICKNESS(FL) AND 1.09(FR). I AM HAVING SPECS ON ROTORS INDEPENDANTLY VERIFIED.*AK

WHILE BACKING OUT OF THE GARAGE MY BRAKE PEDAL WENT TO THE FLOOR. A NEW MASTER CYLINDER AND BRAKE BOOSTER WERE REPLACED AT 5,000 MILES(5-21-2003). AT 15,000 MILES MY BRAKE PEDAL WENT TO THE FLOOR AGAIN, IT WAS TOWED TO THE DEALER WHERE I WAS TOLD THIS IS NORMAL AND IT WAS JUST THE BRAKE SYSTEM CHECKING ITSELF. I WILL BE BUYING A NEW CAR AND YOU CAN BE SURE IT WILL NOT BE A FORD!!!!!!!!!!!!!!!!!*AK

UNUSUALLY HIGH VOLUME OF BRAKE DUST ACCUMULATION FROM FRONT BRAKE PADS ON '03 FORD EXPEDITION. *AK

FRONT BRAKES PRODUCE EXCESSIVE DUST ONTO THE RIMS. *AK

REAR BRAKES NEEDED REPLACEMENT. (NAR) *PH *CB

2003 FORD EXPEDITION . FORD INFORMS ME AFTER ONLY 30,000 MILES THE TYPES OF BRAKE PADS USED DESTROYED THE ROTORS; MUST BUY NEW ROTORS AND PURCHASE THE NEWLY DESIGNED FORD BRAKE PADS WITH SPECIAL SPRINGS AND SUCH TO PREVENT THE FUTURE PROBLEMS WITH PADS THAT EAT ROTORS. BUT , THIS FORD DOES NOT CONSIDERED THIS TO BE DEFECTIVE. TOTAL COST FOR BRAKES ONLY - $ 909.00. *AK