Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| SERVICE BRAKES, HYDRAULIC | |||||
| 06317 | 01/01/2006 | 06125 | 10020132 | Brake shudder. *tt | 07/26/2006 |
| 0514 | 01/01/2006 | 06317 | 10013301 | Brake shudder (rotor thickness variation) due to the new low dust front brake lining used in production, or new linings that were installed per tsb 04-05-02. *tt | 04/14/2005 |
| 17247 | 10/01/2003 | 10004901 | Accumulation of brake dust on the wheels under regulator driving conditions. *tt | 01/14/2004 | |
| SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DRUM - SHOES/LININGS | |||||
| 0411 | 03/08/2004 | 0452 | 10007356 | Brake dust - revised brake linings - vehicles built prior to 12/18/2003. *tt | 06/16/2004 |
| SERVICE BRAKES, HYDRAULIC - POWER ASSIST | |||||
| 052621 | 01/01/2005 | 10019415 | Unintended brake assist. *tt | 03/14/2006 | |
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| SERVICE BRAKES, AIR - ANTILOCK | |||
| 03/14/2004 | 2010 | 2 | 12/30/2003 |
| On sunday, 3/14/2004, i was driving my 2004 ford expedition on dry pavement when the vehicle began to shake with acceleration (15-20 mph). i checked to be sure there were no flat tires and proceeded. once the vehicle was upto 45-50 mph i attempted to brake and the vehicle's brakes did not properly respond. the brake pedal began to vibrate and shake but the vehicle did not slow down. i applied the brakes harded and the vehicle came to a slow stop. once the vehicle stopped a warning buzzer sounded and the vehicles message center stated check advtrac. the advtrac feature disabled and i was able to drive the vehicle home safely. the next day, (today 3/15/04), i drove the vehicle to the ford dealership without event. the dealership nad no idea what the problem was but stated they would contact ford and let me know. this event took place on a clear paved dry flat road. fortunately, there were no other cars in my path of travel. had there been, a collision would have occured due to the failure of the braking system. the vehicle has 2014 miles and the vin is 1fmfu18l24la81246. the vehicle was being operated in the 2high mode. this is a serious system failure related directly to the advtrac system. *ak | |||
| SERVICE BRAKES, HYDRAULIC | |||
| 11/08/2011 | 73000 | ||
| Tl* the contact owns a 2004 ford expedition. the contact stated that while exiting a parking space and applying the brakes, the brake was depressed into the floorboard abnormally. the contact drove the vehicle to a local mechanic and notice brake fluid leaking. the mechanic advised that the radiator supporter was rusted and also caused the brake lines to rust. the mechanic replaced the radiator support unit and the brake line. the contact called the manufacturer regarding the faulty brake lines and the manufacturer stated there was nothing they could do to assist. the failure mileage was 73,000. | |||
| 11/08/2011 | 73000 | ||
| Tl-the contact owns a 2004 ford expedition. the contact stated that while exiting a parking space and applying the brakes, the brake was depressed into the floorboard abnormally. the contact drove the vehicle to a local mechanic and notice brake fluid leaking. the mechanic advised that the radiator supporter was rusted and also caused the brake lines to rust. the mechanic replaced the radiator support unit and the brake line. the contact called the manufacturer regarding the faulty brake lines and the manufacturer stated there was nothing they could do to assist. the failure mileage was 73,000. kmj | |||
| 11/08/2011 | 73000 | ||
| Tl-the contact owns a 2004 ford expedition. the contact stated while pulling out of a parking space the contact applied the brake and the brake went down to the floor. the contact drove the vehicle to a local mechanic and notice brake fluid leaking. the mechanic notice the radiator supporter rusted and also caused the brake line to rust as well. the mechanic replaced the radiator support unit and the brake line. the contact called the manufacturer regarding the faulty brake lines and the manufacturer stated there was nothing they could do. the failure mileage was 73,000. jo | |||
| 01/01/2011 | 80000 | ||
| Tl - the contact owns a 2004 ford expedition. the contact stated that while driving 40 mph and changing gears, he was unable to engaged the breaks. the contact mentioned that he had to drive into a pile of snow in order to stop the vehicle. the vehicle was taken to the dealer who was unable to diagnosed the failure. the manufacturer was made aware of the failure who referred him back to the dealer. the vehicle identification number was not available. the vehicle was not repaired. the failure mileage was 80,000 and the current mileage was 86,000. pm | |||
| 04/17/2011 | 98835 | ||
| Tl* the contact owns a 2004 ford expedition. the contact was coming to a stop and depressed the brake pedal when the vehicle would not stop or slow down. the contact crashed into a pole and a gas meter before the vehicle caught on fire. the fire department was called and extinguished the fire and a fire report was filed. no one was injured yet the vehicle was destroyed. the origin of the fire was unknown. the dealer was not contacted. the manufacturer was made aware of the failure who stated that they will send a representative out to inspect the vehicle. the failure mileage was 98,835. | |||
| 04/17/2011 | 98835 | ||
| Tl-the contact owns a 2004 ford expedition. the contact stated while coming to a stop and depress the brake the vehicle would not stop or slow down it crash into a pole and a gas meter and then caught on fire. the fire department was called and put the fire out; a report was available if needed. no one was injured. the vehicle was destroyed. the origin of the fire was unknown. the dealer was not contacted. the manufacturer was contacted who stated they will send a representative out to inspect the vehicle. the failure mileage was 98,835...mw | |||
| 04/24/2006 | 10000 | ||
| Tl*the contact owns a 2004 ford expedition. the contact was driving approximately 35 mph when the vehicle began to vibrate while the brake pedal was depressed. the vehicle was taken to an authorized dealer for repairs. the technician turned the rotors and replaced the brake pads. the vehicle was taken to the dealer on a second occasion for the identical failure. the dealer advised the contact that the front rotors needed to be replaced and the rear rotors needed to be resurfaced. the manufacturer was notified which stated that the failure was caused by normal wear and tear. the failure mileage was 10,000. the current mileage was 28,000. | |||
| 03/30/2010 | 44000 | ||
| We were involved in an accident. our 2004 ford expedition seamed to fail to respond to slamming on the brakes to avoid collision. we rear ended a car, no one hurt. no air bag deployment at all. #0-35 mph speed. hit car in front of us after he stopped in road for no reason. major damage to our truck. should have been fender bender. | |||
| 10/31/2007 | 1 | ||
| My 2004 ford expedition has had a problem since we bought it from the dealer. the advancetrac will engage on dry surfaces and smooth roads. it will happen anytime of year when the road is dry and should have no reason for turning on. i almost crashed october 31 2007, the abs turned on and i could not steer, i slowly came to a stop in on the wrong side of the road. it was hard to stop while the abs was still engaged the whole time. i then turned off the advancetrac and i drove right to the dealer and told them to fix it. i have taken this car in many times to phil long ford they could never get the car to engage for them. it has happened more than i ever want to count. they have replaced a couple of different things but it still has this problem. thank you for your time!! *tr | |||
| 06/22/2008 | 88000 | 1 | |
| On 6/22, the right wheel bearing assembly failed while traveling ~20 mph. as a result, a fire occurred. i put the fire out in our driveway at home with a water hose. significant damage occurred to the right wheel assembly, bearing housing, 1/e axle, rotor, caliper, brake pads, emergency brake, etc...luckily, were close to home and were not traveling 70 mph. no other vehicles were involved and there were no injuries as my wife and i were able to get all of our children out of the expedition safely. our expedition is a 2004. *tr | |||
| 04/14/2006 | 5 | 12/05/2004 | |
| Brakes have failed to work properly on several occasions. three (3) times when i backed up out of my driveway...brakes completely failed...i almost hit the trees across street in my neighbor's yard. i pumped the brakes vigorously when i realized they weren't working. don't know how i escaped an accident. it happened again when i tried to back up one night when i was away from home in north carolina. i realized the truck was not going to stop - so i threw the gear shift up into forward drive...barely escaped hitting a gas meter on a house.. this would have been a horrible accident. there were 5 people in the truck and 2 people in the bedroom of the house i almost hit. this brake failure on the 2004 expedition is a really bad problem. you drive the truck at your own risk. it is an accident - just waiting to happen again. dealer in north carolina had no clue as to what was happening. the local dealer has no clue....they only say if it reoccurs while the truck is in their possesion, they might be able to discover what is happening. is this a potentially dangerous vehicle? what does ford moter company say about it??? does anyone know? *nm | |||
| 09/16/2006 | 2 | ||
| On 9/16/06 at approximately. 64,500 miles on odometer without any similar problem, i started car at los angeles international airport parking lot #3 with foot on brake. brake pedal went to all the way the floor as engine started and escaping air type sound heard. pumped pedal and each time it depressed less and less until full brake pedal returned. drove and applied brake numerous times without incident until reaching intersection of sepulveda blvd. and west slauson avenue (3.34 miles: per map quest). entered left turn lane applying brake to stop for red light. at approximately 20 mph brake pedal went to floorboard again. could not stop and vehicle proceeded through signal. fortunately oncoming traffic was stopped or there would have been an accident. pumped pedal several times as vehicle coasted forward and full break pedal returned. problem hasn't recurred since. took vehicle to vista ford, woodland hills. service tech could not duplicate problem. (i have seen nine similar complaints on this nhtsa site... all referencing the problem as intermittent and all reflecting the ford dealers service dept. could not duplicate and could not determine source of problem). this needs to be investigated before someone is seriously injured!!!*jb | |||
| 06/12/2005 | 30400 | 1 | 04/15/2004 |
| Air bag/brakes failed. 2004 ford expedition. at 28500 miles brakes and rotor was replaced along with the clutches in the rear two weeks later this accident. noise was still heard in the rear after the repair. car was totaled. *nm | |||
| 08/01/2005 | 8000 | 2 | 06/01/2004 |
| During emergency stop it was noted that the brake pedal went to the floor. suv had less then 8k miles on it. dealer turned the disks and replaced pads and bled brake system. brakes still go to the floor and now have brake shudder at 13k miles. *jb | |||
| 10/11/2004 | 20000 | 3 | 11/25/2003 |
| On three occasions the brakes on my 04 expedition failed. twice was when towing a 5000 lb. trailer, and i assumed the problem was connected with that. but the other day when not towing i almost clobbered the car ahead of me when i had to make a hard stop. on the three occasions the pedal goes almost to the floor with little (but some) braking effect. the ford garage cannot find anything wrong.*ak | |||
| 03/03/2004 | 200 | 1 | 02/20/2004 |
| I purchased a new 2004 ford expedition the front brakes give off huge amounts of brake dust in 100 miles the rims are solid black. i feel this is a safety issue and may result in brake failure. *nm | |||
| 03/14/2004 | 2000 | 1 | |
| While driving 45 mph brakes failed. driver pressed the brake pedal, which pulsated and went down to the floor. somehow vehicle stopped without incident. after the vehicle stopped engine check warning indicator illuminated. the dealer was not sure how to repair this problem. *ak | |||
| 1 | 01/03/2004 | ||
| Excessive accumulation of brake dust was found on the aluminum wheels. there' is tsb 10004901 on this issue, and the manufacturer has a kit that the consumer can purchase for $230.00 plus installation. the kit is not guaranteed to correct the problem, but it will reduce the dust accumulation, per the dealership.*ak *nm | |||
| SERVICE BRAKES, HYDRAULIC - ANTILOCK | |||
| 05/10/2007 | 54100 | 7 | 12/23/2003 |
| Rear a/c actuator suddenly failed with no warning. abs light came on and dealership said that an animal chewed through the wires to the abs computer, which was odd because i live in the city of los angeles where this was unheard off. cost me $688 and the abs light remained on. i don't even have proof that they did anything. transmission stopped shifting into overdrive. dealership said that the abs computer needs to be replaced. cost me $450. abs light went off, but transmission still doesn't shift into overdrive. dealership now says that my overdrive band is worn. they quoted me $3,300 to fix. i have also had 3 break jobs which cost $600 a piece performed in less than 3 years. which i never had this problem with any vehicle i' ever owned. this truck is only 3 years old and has had a tremendous amount of expensive problems.*ak | |||
| 04/17/2005 | 10000 | 3 | 09/03/2004 |
| Dt: the caller's vehiclehad brake failure 3 times. twice in driveway and once whthe ile driving at 30 mph. brake pedal went all the way to the floor. the caller's wife hit the brakes and they would not work and vehicle hit a mailbox before she could gain control of the vehicle. dealer said they couldn't find the cause of the problem. manufacturer said unless they could duplicate the problem they couldn't help him. *ak | |||
| 02/16/2004 | 26430 | 1 | 12/23/2003 |
| While driving my 2004 ford expedition at ~65 mph the car in front of me slowed abruptly. upon pressing the brake pedal, the pedal fell to the floor and the brakes failed to slow the vehicle. i swerved to avoid hitting other vehicle. i removed my foot from the brake and then pressed the brake again and the brake began to operate normally once again. car currently at the dealer although cause has not been found. 1 week prior i had the brakes inspected due a concern where the brake pedal would slowly fall to floor while adding and removing pressure from the pedal (without completely removing pressure) in 5-10 mph downhill stop and go traffic. dealer had told me that the entire brake system had been inspected and that the brakes were fine. *ak | |||
| 10/01/2004 | 35000 | 2 | |
| While driving brakes failed. the pedal went to the floor. consumer lost control of the vehicle, which ran off the road. this happened twice. the second time an accident occurred. *ak | |||
| 06/25/2004 | 1 | ||
| While driving consumer applied the brakes and pedal went to the floor. this caused brakes to lock, and consumer was unable to unlock them. then, vehicle collided into a brick wall. the vehicle was towed to the dealer for inspection. *ak | |||
| 05/13/2004 | 1 | ||
| While applying the brakes pedal went to the floor and a loud buzzing sound was heard from front. both feet were on the brake pedal, and vehicle continued to accelerate. consumer was able to maintain control of the vehicle, and drove it to the dealer for inspection. mechanic placed the vehicle on the diagnostic machine. however, mechanic could not duplicate the problem. *ak | |||
| SERVICE BRAKES, HYDRAULIC - ANTILOCK - CONTROL UNIT/MODULE | |||
| 06/15/2005 | 4000 | 2 | 03/04/2004 |
| My letter to paoli ford to: paoli ford 3/18/06 attn. general manager re: 2004 e.b. expedition purchased 3/04 problems: door rattles, brake failure no ford product to date has required as many service calls as this 2004 expedition. the door rattles have never been totally fixed after7 attempts. i believe that there is a design flaw in the advance trac system that has caused a brake failure on two occasions. i do not intent to wait around for a third time. last summer, i was traveling at approximately 50 m.p.h. when approaching a light in heavy traffic. the brakes failed. the pedal pulsated as if i was on ice, but the pavement was perfectly dry. i avoided a massive rear end collision by taking evasive action, and driving over a berm. the brakes acted as if they had about 10 % of their stopping power. when i called the service department at paoli ford, they suggested i restart the vehicle and turn off the advanced trac button. this did restore the brakes. i dropped the truck off and they replaced some yaw sensor parts under warranty, and declared it safe to drive. this same brake failure has now happened again! the message center indicated 2 advtrac faults, but the service department says that the fault codes scrolled off the system by the time they were able to test it. they suggested that i drive it until the brakes fail again. i will not subject my family to the danger of this situation again! i do not intent to wait around for the next time the brakes fail. ford has designed their traction control system to remove braking power when there is a potential rollover. however, when there is a problem with the yaw sensor, it can remove the braking power while traveling straight on a dry road. ford has eliminated rollover lawsuits, but caused a brake failure in the process. *jb | |||
| SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC - PADS | |||
| 04/12/2006 | 28000 | 5 | 05/07/2004 |
| 1) front end shimmies when brakes are applied. 2) creates a potentially unsafe driving condition, especially in snow or rain. 3) replaced brakes, replaced rotors, had rotors turned...still an issue. *nm | |||
| 12/22/2004 | 1 | ||
| Excessive black dust from brakes of new 2004 ford expedition. *jb | |||
| 11/28/2004 | 5000 | 1 | 02/28/2004 |
| Had noticed large amount of brake dust (1/8 in) on mainly front wheels of 2004 ford expedition e b-veh had less than 5000 miles- and brakes did not function as i believed should. read your link re manufactured date being prior to december 03 that brakes would be replaced.took to ford dealer 12 13 04 and had replacement per service bulletin (dangerous situation)-have had 12 concerns to quote ford-a/c-rear end repaired-outside mirrors click motor replaced (still jumps)-window mech bad-tire pressure display-ford customer service advised on 12-15-05 just continue to have repairs made-no other option-have been to dealer with 12 concerns -kept veh 8 days one time-having to go back with same concern not being taken care of-this model is really a lemon-although ford is aware of the brake situation and tsb issued the consumer is not notified as per ford customer service -you have to wait til something happens (if you or family is still alive) -vin: 1fmru17w14la15022. *ak | |||
| 01/04/2003 | 200 | 1 | 12/01/2003 |
| Huge amount of brake dust on front wheels happening in normal driving conditions . *ak | |||
| 01/20/2004 | 2000 | 1 | |
| Massive brake dust accumulation. *ak | |||
| 01/20/2004 | 1 | ||
| My 2004 ford expedition is 31 days old and has excessive brake wear, which i consider a safety issue. the brake dust, in less than two thousand miles, is caked on the front wheels and extends the entire length of the running boards on each side. the amount of brake dust covering the wheels and running boards indicates excessive wear of the brake pads. i am greatly concerned that the brakes will fail prematurely. ford motor company does not consider this an issue.*ak | |||
| SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC - ROTOR | |||
| 04/12/2006 | 28000 | 5 | 05/07/2004 |
| 1) front end shimmies when brakes are applied. 2) creates a potentially unsafe driving condition, especially in snow or rain. 3) replaced brakes, replaced rotors, had rotors turned...still an issue. *nm | |||
| 06/20/2005 | 8000 | 2 | 10/02/2004 |
| Shaking in steering wheel when brakes are applied. took to dealer at 8k miles - dealer said front rotors are warped - they would only turn them. problem occurred again at 20k miles. dealer (same one) would not say what the problem was, only that heat causes them to warp - i requested new rotors but dealer only offered to turn the rotors again and warned me the rotors were so thin they could not be turned the next time. still no explanation of what is wrong with the brake system. heavy brake dust on front wheels | |||
| 01/26/2005 | 7000 | 1 | 08/30/2004 |
| Noticed a vibration and pulsation whenever applying brakes. 2004 expedition with only 7k miles. ford dealer noted the front rotors had excessive run out and were machined down. if the original rotors weren't strong enough to handle even 7000 miles then how is machining them thinner going to resolve the problem? i believe the rotors should have been replaced with stronger parts.*ak | |||
| 12/26/2004 | 14596 | 1 | 01/15/2004 |
| Excessive front brake wear on 20004 ford expedition. vehicle has 14,000 miles and front brakes are gone. rotors cannot be turned due to excessive ware. front inside calipher cannot and will not stay tight. they keep sliding causing heavy groove wear in the rotors and heavy front end shaking and wobble during stopping. the brakes often fade to the point where the emergency brake must be used for stopping. the ford dealer recommended replacing the pads and rotors but not with oem parts as that is what the problem is. i was urged to go to after market brake components. i did and there is no brake dust, fade, squeak or shake. | |||
| 11/03/2004 | 8000 | 1 | 10/27/2004 |
| While driving at 35 mph front end started to shake: also the tires started to wobble severely when the brakes were applied. consumer took vehicle to the ford dealer, and the mechanic determined that the rotors were warped. mechanic turned the rotors instead of replacing them. *ak *tc | |||
| 07/06/2004 | 16500 | 2 | 02/16/2004 |
| 2004 ford expedition suv - steering wheel pulsates when brakes applied. returned to dealer service dept and they regroung the front rotors - this occured @ 16500 miles and @ 25600 miles. dealer advised that it is not a good design by ford motor company to large a vehicle for the size of brake rotor that they overheat and then warp ?? dealer advised i was applying the brakes too hard.*ak | |||
| SERVICE BRAKES, HYDRAULIC - PEDALS AND LINKAGES | |||
| 05/26/2005 | 8400 | 4 | 11/27/2003 |
| While driving my ford 2004 expedition eddie bauser, the brake pedel will go all the way to the floor, & the braking system will failed to work, vehicle will not stop, this happens 4 time, & the dealer ( brandon ford ) & ford refuse to help us, the dealer after looking at the vehicle every time said nothing happens to the brake, we are afraid to drive the vehicle, for we might not be lucky the next time it happen, the last time it happen was on may 26, my wife was driving with the kids when it happen, she had to pull onto the side of the road in order to avoid hitting the cars in front of her which cause her to hit at road sign, which cause about $2100 in body repair cost, we need to file a complaint against brandon ford & ford motor company for not thinking about their customer safty & life & family. thank you. | |||