Ford Excursion premature wear problems

Filed Nov 8, 2006 · Suspension · 74,000 miles · OH

Dt*: the contact stated the suspension: front control arm: upper ball joints and the suspension: front control arm: lower ball joints had prematurely worn out. The old parts were not manufactured with grease fittings as were the replacement parts. The upper and lower ball joints were replaced by an independent mechanic. The manufacturer was notified.

Filed Feb 10, 2006 · Brakes · 54,890 miles · NV

Brake rotors warp excessively. Just purchased used vehicle, had to have the rotors turned and brake system serviced after 5,000 miles. Vehicle would vibrate excessively upon application of brake. Ford service representatives that inspected the brake system stated that the pads looked almost new. In doing research on the internet this exact scenario seems to be playing out with 2000 - 2004 excursion models. Other owners claim to have the brake serviced and rotors turned every 15000 - 25000 miles. It seems that the rotors are not adequate to handle the weight of the vehicle with out needing excessive service on a frequent basis.

Filed Dec 9, 2005 · Brakes · 40,000 miles · CA

Dt: the contact stated while driving at 40 MPH the vehicle rattled. The vehicle was taken to the dealership. The first time the front rotors had to be turned. Several thousand miles later the problem recurred. He took the vehicle to the dealership again. This time it was the rear wheel rotors. The rotors were turned. The third time he took the vehicle to the dealer have it serviced. This time the brake pads, and rotors were turned. The dealership told him it was the design of the brake system, the rotors were too small for the brake system. All repairs have been made at the contacted expense. *ak updated 1/19/2006 - the front rotors warped which caused pulsation while braking.

Filed Nov 15, 2005 · Brakes · 104,000 miles · TX

Front disc brake rotors warp under normal driving conditions. This results in extremely violent shuddering and shaking of the steering wheel while braking at speeds over 40 MPH. Rapid braking at freeway speeds are high risk for loss of control and collision. I bought this excursion used with ~48,000 miles and have had the rotors resurfaced at ~ 60, 000 and 84,000 mi. At 93,000 miles I had to replace all 4 rotors because of repeated shuddering from rotor warpage and wear which cost me over $500 on top of the $400 I spent at 84,000 miles for a brake job. Six months and 14,000 miles later I am having the same problem and now the dealer tells me there is a ford service bulletin recommending a new type of pad. They also told me they have four other excursion owners that are having the same complaints and safety concerns requiring similar repairs. The front rotors are insufficiently engineered for the size and weight of this vehicle, and presents a safety risk for excursion owners as well as surrounding motorists. Ford knows they have a problem but instead of doing the right thing and fixing it they are bleeding consumers for repairs of a faulty design while the government does nothing about it.

Filed Feb 21, 2005 · Suspension · 79,000 miles · WA

Multiple warped rotors. Failed wheel bearing which by ford design are not serviceable. Dealer told me not safe to drive, yet charged me for wht is a design flaw, a serious safety issue, possible lock up. Common knowledge on web that grese leakes on to rotors causing slow stopping, and warping, and you can not add grease.

Filed Sep 21, 2003 · Brakes · 31,189 miles · NV

Front rotors rusted in center area between rotor brake surface. At 30,000 miles my 2002 ford excursion started to shake violently when braking at speeds above 40 MPH. Luck for us we were driving in lower speed conditions in residential traffic. I inspected the brake pads and rotors for problems and found large amounts of rust decay in the rotors causing the warping to the rotors. I have serviced the brake system and replaced the front rotors and pads with excellent results. I have kept these rotors if any one should like to further look into this situation. We live in the desert with very low rain or snow. Now salts are used in my home area. I have never seen such corrosion to and important safety system. If this is a problem that could cause harm to others I would like to get the word out. I regularly respond to accidents and vehicle equipment failures as firefighter/medic. Regardless of fault it is a professional duty to at least make this notification.

Filed Feb 27, 2003 · Brakes · 17,000 miles · VA

I too have experienced warped rotors under normal operation. I have owned my 2000 excursion since new and have already had my rotors resurfaced once. They lasted approximately three months before having to have them done again. My last visit cost me $500 and I expect nothing less from the dealer this time. The harmonic period seems to be most pronounced when braking at 50 MPH with the severity decreasing at a standard bell curve above and below that speed. I am concerned of my safety when having to brake at highway speeds from loss of control or failure. Based on the complaints I have viewed, I would be in favor of a class-action suit with a redesign or buy-back remedy.

Filed Jan 19, 2003 · Brakes, Seats · 10,000 miles · NC

I own a 2000 ford excursion and have had problems with the rotors warping since new. The dealers have said I was the only one with this problem but after seeing this web site I see that is not true. Also I had the bearings go out in the right front wheel almost leading to the tire falling off if my wife had not noticed it in time. The rotors have been replaced twice have been turned at least every 15,000 miles since new I have around 80,000 miles now. The dealer did the brakes three times until the warrnty ran out at 36,000 miles I have had them fixed myself since then. This truck is said to be heavy duty and I only tow a camper with it twice a year 60 mile round trip I feel like I should not be having this kind of problem. The severe shaking that is caused by this makes if difficult to drive for my wife since she is the primary driver of the car. I cannot wait till my lease runs out so I can get rid of this car. The dealers will not help me at all. Thank for and help you might can give william andrews

Filed Nov 16, 2002 · Brakes · CA

Rotors warped at 32,000 miles, warped again at 34,000, then at 35,000, warrantied twice. Truck won't go more then a few thousand miles without warping rotors made first 32,000 on factory since tried two different aftermarket after 4 failures from ford. My driving hasn't changed only the front rotors. Dt

Filed Mar 18, 2002 · Brakes · CA

Front disc brake rotors warp under normal driving conditions. This results in extremely violent shuddering and shaking of the steering wheel while braking at speeds over 40 MPH. Rapid braking at freeway speeds are high risk for loss of control and collision. Because of safety concerns I have had the rotors resurfaced at 16, 000 and 25,000 mi. At 31,000 miles I had to replace the rotors because of repeated shuddering from rotor warpage and wear. I have asked four other excursion owners and they have the same complaints and safety concerns requiring similar repairs. Front rotors are insufficiently engineered for the size and weight of this vehicle, and presents a safety risk for excursion owners as well as surrounding motorists. Even when serviced properly as outlined, shuddering returns quickly.