Three problems related to brake disc have been reported for the 1997 Ford Explorer. The most recently reported issues are listed below.
Failed annual veh. Inspection due to defective front brakes. Cause of failure extremely heavy rust in hub area that spread onto the outside rotor surface heavily damaging the rotor surface and brake pad. This was not a wear & tear situation as the inside pad and rotor were not damaged & showed no abnormal wear. Mechanic reported seing this problem on a number of low-mileage Ford Explorers. He felt that this amount of rust was due to a defective casting.
Vehicle experienced front end vibration . Problem occurred at take off or slow down speed. Been inspected by three different dealers, and informed that nothing could be found. Also resurfaced front brake rotors and pads.
The brake pedal is too close to the accelerator pedal. In a panic stop situation, the drivers foot will depress the brake pedal fully and at the same time open the throttle over halfway, engine revs to nearly 3,000 rpm. I have nearly wrecked this truck on five different occasions. If one is a right foot heel and toe brake operator with a normal size adult shoe, this serious problem will happen. This has occurred since the vehicle was brand new.