Brake Hoses, Lines/piping, And Fittings problems of the 2003 Ford Expedition

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.

The brake line that is routed to the rear brakes rusted completely through, causing me to lose all braking function hence, control of my vehicle. I had to run off into a ditch to miss a slowing vehicle. After I had come to rest in the ditch there was an engine fire caused by brake fluid spraying onto the hot engine exhaust manifold. Fortunately, I had a fire extinguisher on board, so I was able to put the fire out before there was any damage. The interesting thing about this incident is that there is another line that runs parallel with the defective line that shows zero evidence of corrosion.

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.

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.

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.

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?.

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.

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.

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.

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