Two problems related to brake disc rotor have been reported for the 1999 Ford Explorer. The most recently reported issues are listed below.
Brake rotors warped and required replacement 2 months after brake service which included machining rotors in (4-24-04). Follow up service (8-16-04) for problem found warped rotors on left side, in which Ford dealer service charged for replacement. (10-15-04) right side rotor now exhibiting same defect.
Consumer experiencing thumping noise while driving and loss of brake effectiveness. Vehicle checked by dealer, who advised that rotors were pitted (rusted from inside out). As rotor pitting got worse, it caused excessive wear. Damaged to brake pads. Consumer purchased an extended warranty but the dealer refused to replace the rotors as being defective. Consumer stated that the metal being used in the manufacturing process caused the rotors to rust.