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Brake Hoses, Lines/piping, And Fittings Problems of Ford Expedition



Ford Expedition owners have reported 35 problems related to brake hoses, lines/piping, and fittings (under the service brakes category).

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2000 Ford Expedition 1
Failure Date: 04/21/2014

Brake line above fuel line completely rusted through. Luckly I was stopped for fuel and lost brake pressure. Upon inspection at my local garage, all brake lines were rusted to the point all were replaced. Upon closer inspection, the rear suspension parts are rusting underneath the coating that covered the suspension parts. I realize the vehicle is 14 years old, but I have much older vehicles that have zero rust. Just for the record, we have years that we have no snow, so my exposure to salt roads is very limited. Items such as brake lines and suspension parts should be made of a better quality material. After all, this vehicle still has the original exhaust system! regardless of age, with just over 77k miles this is a serious safety issue.

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car image   Brake Hoses, Lines/piping, And Fittings problem of the 2005 Ford Expedition 2
Failure Date: 03/22/2014

I have talked to a few other owners of Ford Expeditions (later models 2004-2008) and there is a definite issue with rust and other components rusting out. It seems to be a serious issue with rust esp when the brake lines are basically all rusted out in the front of the vehicle. Also the cross member frame underneath has a lot more than acceptable amount of rust, never seen this much even with a truck I have now a 1997 Dodge with 190,000 miles doesn't even come close to the rust I see with the Ford. Rust bubbles on the rear lift gate handle area and just about all around the window areas and the hood. Mind you that the time we've had the vehicle only maybe a handful of times it was out in snow or even rainy weather - low miles for the year 67,000/8 years+. The lines and rust repair will cost money $$ to fix I believe that Ford knows there's an issue and stiffs the consumer knowing that the materials rust out causing a very unsafe vehicle to drive. Anybody for a class action lawsuit here?.

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car image   Brake Hoses, Lines/piping, And Fittings problem of the 2004 Ford Expedition 3
Failure Date: 02/27/2014

I was driving up to a traffic light, in my 2004 Expedition. Coming to a stop. A good thing, I was not driving to fast, or had to make a sudden stop quickly. There was not a vehicle in front of me ,thanks to god! had my foot on the brakes, and the pedal went down to the floorboard. Now I have no brakes at all. The indicated lights, for brake fluid came on. So, I stop to refill brake fluid. There, I notice a busted brake line. I have only seeing this in the movies, I have been driving for 30 now. I could have lost my life, or taken someone else life. After looking online. I have seeing, others with some of the same problem, with the 2004 Expedition. But there no recalls, and I know Ford motor have heard of this, and others too, that is the place to do something for the safety of the people(small). But nothing is being done! .

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car image   Brake Hoses, Lines/piping, And Fittings problem of the 1999 Ford Expedition 4
Failure Date: 12/05/2013

The vehicle was being driven in normal operation when the brake pedal went to the floor and the brake system became ineffective. Vehicle was towed to a brake shop where the brake line on the frame on the driver's side near the door was found to be corroded through and leaking. The brake shop found all metal brake lines corroded and recommended replacement.

See all problems of the 1999 Ford Expedition.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2002 Ford Expedition 5
Failure Date: 09/18/2013

Brake line ruptured in rear of vehicle when pulling into service station hauling my travel trailer. Was told the line was completely rusted through and this is a common problem on these model year vehicles. I find totally crazy to find brake lines rusting on a vehicle of this age. I was also told the rear control arms need to be replaced because of the rust. I know this was an issue on the windstars and it was recalled Ford need to take care of this. Thank god it happened at the station and not hauling my kids to the campground. This needs to be addressed due to the fact there are thousands of these vehicles still on the roads. I know if I call Ford they will tell me its not in warranty that's why I contacted you. They cover airbags and seatbelts for life they should cover brake lines.

See all problems of the 2002 Ford Expedition.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2004 Ford Expedition 6
Failure Date: 07/05/2013

Was driving when brakes went completely out when I went to stop at a stop sign. . Cause due to rust corrosion . Brakes giving out could have caused a fatal car accident . Rust has damaged all brake lines and fuel lines . Rust is now moving up the vehicle. Brake lines and fuel lines should have a protected coating or made with a non corrosion metal. I had no idea that my brake line was rusted out till my brakes gave out. These vehicle need to be recalled and have new lines. Also have a protected coating applied under the vehicle to stop rust. Very very dangerous driving around not knowing that you have rust under your vehicle eating away at your brake lines and fuel lines.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2001 Ford Expedition 7
Failure Date: 07/02/2013

Ford Expedition 5. 4l 2001 - sudden brake failure while traveling 25 mph in parking lot. Brake lines rusted through caused sudden brake failure. Car had undercarriage cleaning frequently during winter months and there was no indication of any problems. When replacing the brake lines, owner was informed that the upper and lower rear control arms were rusted through as well and that immediate replacement was necessary to avoid the rear track arm failure which which results in dropping the rear axle and complete loss of vehicle control. Vehicle was purchased new in June 2001 and maintained continuously. Owner has possession of corroded control arms after repair for evidence in NHTSA investigation. Nhtsa is encouraged to contact the owner of vehicle for inspection of failed parts for investigative support. . This is a manufacturers defect and vehicles need to be recalled and parts replaced to avoid loss of vehicle control, accidents, injury and fatalities due to Ford motor company negligence.

See all problems of the 2001 Ford Expedition.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2003 Ford Expedition 8
Failure Date: 05/18/2013

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

See all problems of the 2003 Ford Expedition.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2005 Ford Expedition 9
Failure Date: 08/16/2012

Driving the vehicle and I attempted to stop and the brake pedal went to the floor, even after pumping the brakes. Soon afterward the low fluid light went on. I had the vehicle taken to my licensed mechanic who diagnosed the problem as a rusted through brake line. Several other locations were heavily rusted and leaking as well. I was very fortunate not to hit anyone, especially since I had 5 children in the vehicle with me at the time of the incident. I have been the only the owner and ordered the vehicle new from Ford. This vehicle is lightly used and not garaged.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2003 Ford Expedition 10
Failure Date: 06/14/2012

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?.


 
car image   Brake Hoses, Lines/piping, And Fittings problem of the 2008 Ford Expedition 11
Failure Date: 09/04/2011

On September 4, 2011 attempting to apply my brakes due to a vehicle that abruptly stopped without warning my vehicle would not stop feeling as if the brakes were not gripping I hit the rear of the vehicle in front of me. Prior to the accident the Ford dealership changed the rear brake to include installing a new rear brake line kit stating there was nothing wrong with the front as they had not worn down yet. Not know much about abs I inquired about why the rear brakes were worn and the front brakes were still good, I cannot remember the explanation the service representative gave but I felt it was not right. Six months later my brakes donã‚t allow me to stop when an emergency arises putting my children and myself in danger along with the people in front of us had we already been on the freeway. I canã‚t say for sure if it was the front or the rear brakes that slowed the vehicle down but it did not attempt to stop coming into a downhill curve unto the freeway. There was no hesitation in the brakes no matter how hard I pressed them to stop. After having my vehicle checked at the body shop it was determined there is a problem with the abs but Ford is refusing to acknowledge the problems.

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car image   Brake Hoses, Lines/piping, And Fittings problem of the 2000 Ford Expedition 12
Failure Date: 06/15/2011

Brake lines failed and lost 90% of brake power.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2006 Ford Expedition 13
Failure Date: 09/08/2010

The contact owns a 2006 Ford Expedition. The contact was traveling 35 mph when the brakes on the vehicle failed. The vehicle was taken to the dealer, and the contact was advised that the brake lines had rusted through. The manufacturer stated that corrosion damage to the vehicle is what caused the brake failure. The contact has filed a complaint with the manufacturer. The contact feels that the corrosion should not be a factor because they do not live in a snow environment. The failure mileage 66710 and the current mileage 68000.

See all problems of the 2006 Ford Expedition.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2000 Ford Expedition 14
Failure Date: 09/06/2010

Brake failure due to brake line rust.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2003 Ford Expedition 15
Failure Date: 08/15/2010

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.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2003 Ford Expedition 16
Failure Date: 03/01/2010

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.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1998 Ford Expedition 17
Failure Date: 06/27/2008

The contact owns a 1998 Ford Expedition. The contact stated that the brake light illuminated. He turned the vehicle around to return home and the brake pedal extended to the floor when it was depressed. The vehicle continued to roll forward, and the emergency brake had to be applied. The contact inspected the brake components and noticed several failures with the front and rear brake line. He called the dealer and asked if Ford would cover the cost of the repairs, but was informed that the vehicle was out of warranty. The failure and current mileages were 57,295. Updated 07/29/08 the consumer stated the brake line failed due to corrosion. The consumer stated the material that was used was defective. The brake line should have been made of stainless steel or other corrosion reistant material. Updated 08/07/08.

See all problems of the 1998 Ford Expedition.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1997 Ford Expedition 18
Failure Date: 05/28/2008

The contact owns a 1997 Ford Expedition. While driving 45 mph, the contact attempted to stop the vehicle and the brake pedal nearly touched the floorboard when it was depressed. The contact was able to stop the vehicle; however, the stopping distance had doubled. The contact examined the vehicle and noticed that the brake line was extremely rusted and had a pinhole. The vehicle has not been diagnosed by the dealer. The current and failure mileages were 113,000.

See all problems of the 1997 Ford Expedition.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2003 Ford Expedition 19
Failure Date: 03/06/2008

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.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1999 Ford Expedition 20
Failure Date: 02/01/2007

Failure of rear brake supply line rubbing against steering coupler, causing replacement of brake line. I have sent a certified letter to Ford motor company advising them of this malfunction, and have never received a reply from them. I can furnished a copy of this letter with the problem outlined if needed.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2006 Ford Expedition 21
Failure Date: 12/11/2006

2006 Ford Expedition limited. Consumer writes in regards warranty repair dispute and driver's side power window being extremely slow in the closing operation the dealer lubed the window and stated there was no problem found. After complaining several times about the window, the dealer finally determined there was a problem. However, the consumer was informed the parts and labor were not covered under the extended warranty. The consumer stated the problem existed going back to Dec 11, 2006 and the defect was not addressed or corrected while the vehicle was under the original factory warranty. The consumer stated he should not be responsible for repairs that were callously overlooked and ignored by the dealer. Also, the lower radiator support to the body mount was severely rusted and showed signs of actual material failure. The consumer stated the condition can and will evolve into the root cause of both mechanical and safety related failures. The major body and front frame support failing under driving conditions could lead to engine failure, and loss of control of the vehicle. The most serious safety concern, was the front brake lines which were showing signs of serious rust. The dealer informed the consumer the lines could only be replaced under warranty if there were signs of leakage. The consumer stated corrosion in the form of rust would compromise the integrity of the steel brake lines, allowing brake fluid to leak out resulting in a total loss of braking power. The left rear door would not open from the inside, the driver's front door had to be slammed in order for it to close properly, the front axle drive pinion was leaking and had to be replaced.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1999 Ford Expedition 22
Failure Date: 12/08/2006

I have a 1999 Expedition with 90,000 miles. In early December of 2006, in heavy evening traffic, a car suddenly pulled in front of me and came to a quick stop. I applied the brakes very hard and the pedal went to the floor. I managed to avoid hitting the car that stopped in front of me, but my brakes were gone and I had to limp to the side of the road. Upon inspection, I found that my brake line to the left rear brake had corroded and failed. I got the vehicle home and on a neighbors lift and found that all my brake lines had corroded and needed to be replaced. I had a similar problem with the brake lines on my 1993 econoline that also corroded at about 90000 miles. It appears to me that the brake lines in these vehicles were made from cheap metal and that the manufacturer should look into this problem as it appears to be quite a common occurrence. I replaced all brake lines, including the lines from the master cylinder and to the power assist unit. The old parts were thrown away.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1999 Ford Expedition 23
Failure Date: 12/08/2006

: the contact stated while applying brake pressure at 25 mph on a city street, there was a loss of braking power, and an increased stopping distance. Although no crash occurred, the vehicle was towed to an independent repair shop, who determined the steel pipe fittings,hoses, and connections of the brakes were corrosive, and needed to be replaced. Additionally, it was determined the corrosion was due to use of inferior metals. The manufacturer was alerted.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1999 Ford Expedition 24
Failure Date: 08/06/2006

Lost brake pressure. Found leak coming from frt lh brake line. Fitting between metal and rubber brake lines had rusted and fatigued to the point of failure. Lost all brake fluid and ruined frt lh rim due to corrosive property of brake fluid. Purchased replacement part at local dealer. N/g brake line available for review.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1997 Ford Expedition 25
Failure Date: 12/14/2005

Sudden and catastrophic brake failure caused by rupture of rt. Front brake hose, loss of all fluid and total failure of brake system. Vehicle was stopped by use of emergency brake pedal. No casualty but as incident happened without any warning in a hospital parking lot consequences could have been dire. Original purchase dealer maintained vehicle on schedule: most recent service and inspection in August 2005. Vehicle garaged with 96,000 mi.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1997 Ford Expedition 26
Failure Date: 07/28/2005

The brake lines rupture with no warning. The vehicle has absolutely no brakes. The brake pedal goes straight to the floor. If in traffic, this brake line rupture could cause serious injury or death. Brake lines had to be replaced.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1997 Ford Expedition 27
Failure Date: 06/27/2005

On June 27, 2005 while driving about 65 mph the consumer heard a noise. And upon stopping, the consumer noticed the spare tire fell off. No damage to the vehicle was reported. The cable broke completely off, and the tire was gone. Owner called Ford, and they were not concerned. The brake line ruptured.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1999 Ford Expedition 28
Failure Date: 06/19/2005

The consumer stated that the brakes failed and the vehicle lost all braking power and the pedal went to the floor. The vehicle was taken to a local mechanic, and he stated that brake lines corroded. They corroded in the box frame under the driver's door and the brakline broke allowing all of the braking fluid run out. This happened on June 19, 2005. There were no injuries and no crash. This was due to the fact that the vehicle was on a level road and only going 25 mph.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1997 Ford Expedition 29
Failure Date: 01/17/2005

The car is a 1997 Ford Expedition. The front to rear brake line corroded and failed. This happened coasting into my driveway. Even though it is a split system the braking left was minimal. The partition between the front chamber and the back didn't seem to leave enough fluid in the front chamber to allow effective remaining braking. Not to mention the brake line corroding through in less than 8 years. I had the brake line replaced but did not retain the old brake line. The cost was $623. 04.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2003 Ford Expedition 30
Failure Date: 11/04/2004

Consumer stated brake line wore out prematurely, and excessive brake dust was produced.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2000 Ford Expedition 31
Failure Date: 06/08/2004

My wife parked our 2000 Ford Expedition at work around 8:30 a. M. Two hours later it was on fire. After many conversations with marshall mize Ford they told me that the cause of the fire started in the brake system. They said that brake fluid leaked on my manifold and sparked a flame causing my car to burst into flames. I was under the impression that brake fluid was not flammable, especially after sitting for two hours it should not have even been hot enough. My truck was fixed and we have not had any problems with it yet. The fire started in the engine compartment on the left side. The fire was quickly put out causing there to be only $6500 in damage. Parts replaced consist of the main wiring harness, the components of the brake system under the hood, and the cruise control system. If needed we can fax a complete invoice of all parts and labor.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 2000 Ford Expedition 32
Failure Date: 09/09/2003

After parking the vehicle in the driveway, some fifteen minutes later the vehicle had flames coming from the hood. The consumer stated, the brake fluid leaked out of the cruise control onto the wiring harness.

car image   Brake Hoses, Lines/piping, And Fittings problem of the 1997 Ford Expedition 33
Failure Date: 08/14/2002

When applying brakes, brake line cracked and started to leak fluid. It was hard to stop vehicle. Dealer notified. Consumer states that the fluid sprayed into the cylinder, consumer had to replace spark plugs and wires.


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