2003 Ford Expedition: brake failure

Filed Jul 11, 2019 · Electrical, Engine · 250,000 miles · FL

The truck would just turn off while driving at 55 or 60 miles an hour , no steeringwas on highway ,no brakes put in neural to get to side of road with cars all around me .this has happened 3 times, then it would not start at all when fulled up with gas, had to be towed, then when I was down to 1/4 tank ,would not turn over, had gas in it too, but would not start, had to be towed in shop now again 3rd time ,had problems with the door agar going off had senor replaced still comes up

Filed Feb 4, 2017 · Brakes · 113,789 miles · VA

Experienced a complete brake failure after a 6 hour drive in heavy traffic from nj to va. Parked the car in the driveway for 30 minutes, and upon backing out of the driveway, the brake pedal went to the floor. Parked the car and found brake fluid on the ground. Found brake line rusted through on the cross support under the engine. This is a serious issue that could have resulted in an accident and major injury had this occurred on the drive in heavy city traffic. The vehicle has 113000 miles on it. We have had other manufacturers vehicles with over 200000 miles and no brake line issues. This is clearly a defective part/design issue and due to the safety risk, ford should take action. We had a 1990 f150 that had the same issue in 2002 at 100000 miles. We will be checking our 2004 f150 very carefully.

Filed Nov 22, 2016 · Brakes · 169,000 miles · LA · crash · 1 injury

Tl* the contact owned a 2003 ford expedition. While driving 15 MPH and making a sharp right turn, the brakes and emergency brake failed without warning. The vehicle crashed into two parked vehicles. The air bags deployed. A police report was filed. One passenger located in the rear seat sustained a fractured neck, which required medical attention. The vehicle was towed to a hotel. The manufacturer was not made aware of the failure. The failure mileage was approximately 169,000.

Filed Feb 3, 2016 · Brakes · 71,000 miles · IL

My vehicle experienced total brake failure as I approached a four-way stop intersection on a rural county highway. Inspection by auto repair technicians revealed my brake lines had rusted and had experienced several ruptures. The technicians said the rust was the result of ford's decision to install steel brake lines in the vehicle, rather than aluminum. When exposed to the salt prevalent on local roadways in the winter, they easily rust out long before the vehicle even approaches the beginning of the end of its life.

Filed Dec 3, 2015 · Brakes · 116,785 miles · KY

Abrupt, no warning(on digital dash) loss of braking ability. On stopping while pulling in a parking space in a parking garage, brake pedal went to the floor. Vehicle did stop without hitting concrete wall. Very scary getting the vehicle out of the garage from the 5th floor to be placed on a roll back. Dealer states brake lines have rusted and drained brake fluid causing catastrophic brake failure. Stated they have seen this before

Filed Jul 23, 2013 · Brakes · 110,000 miles · MD

Tl* the contact owns a 2003 ford expedition. The contact stated that while driving approximately 10 MPH, the brake pedal dropped to the floorboard as there was a loss of braking capability. The contact stated that the ABS warning light also illuminated and the emergency brakes had to be used in order to stop the vehicle. The vehicle was towed to a dealer where it was diagnosed that the brake lines were completely rusted and needed to be replaced. The manufacturer was not made aware of the failure. The vehicle was not repaired. The approximate failure and current mileage was 110,000.

Filed May 20, 2013 · Brakes · 89,800 miles · NJ

I previously reported 3 failures of the brake system on this vehicle due to corroded brake lines under the federal safety agency id# 10491754. This past weekend I just had a fourth brake failure due to a corroded brake line in 11 months. This brake line runs along the left front below the engine bay.

Filed Jan 7, 2013 · Brakes · 81,743 miles · NJ

Brake line running across the front end of the vehicle ruptured due to rust causing loss of brake fluid and loss of braking. I had a local garage replace the ruptured line and inspect the other lines. I was advised they were all rusted but they did not see a need to replace them at this time. In october 2012 I had another brake line rupture, this time it was a brake line running along the frame rail on the driver's side to the back brakes. This also caused a loss of brake fluid and loss of braking. I had it repaired at a different repair shop. I also had him inspect all other lines and again I was told the other brake lines were rusted but he saw no reason to replace any others at that time. On january 6, 2013 I had another brake line failure near where the brake line failed in october 2012 (the other brake line running parallel) again causing a loss of brake fluid and loss of braking. Both repair facilities informed me this is a common problem. I also went to different repair facility to have maintenance performed when they saw my new brake lines, they asked what happened. When I told them they said, "oh it's a common problem" I can not understand how the federal government allows vehicle manufacturers to make brake lines out of a material so prone to corrosion. There is no other safety device on a vehicle more important than the brakes. What good are the anti-lock brakes you mandate if the brake lines fail?

Filed Feb 7, 2011 · Brakes · 18,535 miles · PA · crash

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

Filed May 4, 2010 · Brakes · 45,000 miles · NY

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.

Filed Nov 10, 2008 · Electrical · 83,000 miles · OH · fire

Loss of brake lights to 2003 ford expedition, took it into dealership they found a fire in overhead wiring harness. Ford claims to have no problems with harness. None of these wires were visible to us , but had melted the underside of overhead compartment. Visible burn marks on metal interior of roof. All overhead wiring has to be replaced.

Filed Mar 7, 2008 · Brakes · 153,208 miles · SC · crash

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.