Brake Disc Rotor problems of the 2003 Ford Expedition

Rotors needing to be replaced at low mileage on Ford Expedition 2003- or newer and 2004 Ford f150's 2003 or newer.

On August 26,2006 took my SUV to dealer to have it checked out because the front end was shaking really bad. Was told that it needed to have front and rear rotors replaced had another dealer check out only need front rotors replaced had them replaced. On sept 8, 2006 took back to dealer because I heard a whinning noise thought it was the power steering fluid low. It checked out okay dealer check it and was informed that the power steering pump was bad had it replace. Picked up my SUV and it was still making the same noise. Was told to drive for two weeks to let air bleed out line and bring back in two weeks call them to let them know that the noise was still there took to dealer. Nothing was done about it. Call the Ford customer service line and mailed them a letter about what was going on. They told me to take my SUV to another Ford dealer did that was told that the power steering pump was bad that I had put on in Aug. And that something was causing them to go bad. The steering rack is the problem. I call the dealer where I've all of my work done on my SUV and talk to the general manager. He was rude and hung up in my face I call back I'm going to take my SUV to them tomorrow oct 27,2006 and see if we can come to terms to get my SUV fix. But I've see many complaints about the same problem that 'm having.

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.

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.

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.

Front brake rotors completely worn down after only 23,000 miles. Seems to be a chronic problem with this year/model.

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. The dealer replaced the brake fluid because it was burnt. The consumer suspected there was pressure on the brake pads probably from the abs.

Excessive brake dust accumulation since new. Rotors have been turned once and now need to be replaced with pads at 23,600 miles.

Brake rotors wore out prematurely.

Excessive wearing of rotors and pads. Front (right & left) brake pads needed to replaced at 21,000 miles, worn down to antirattle ring and rotors were scortched (ove heated) and also needed to be replaced.

Front rotors wore out prematurely with less then 25,000 miles on the vehicle. Front rotors were replaced three times by the dealer.