Brake Disc Caliper problems of the 2004 Ford F-150

The rear brake lines failed. The rubber line from the caliper to the steel line on the rear axle separated, first on the drivers side and about three weeks later on the passenger side. On the first occasion I was just leaving my garage and on the second occasion I was pulling into a parking spot. The steel fitting that holds the rubber line to the steel line was so badly corroded that it literally disintegrated, allowing the rubber line to separate from the steel line when the brakes were applied.

I noticed my brakes pulsating when applied. The dealers service tech told me the front brakes were not releasing fully and had warped the rotors beyond repair. The caliper pistons had "cocked" in their housings, destroying the front calipers. The repair cost over $1,400. The risk is that the brakes would bind, fail to disengage when applied, and cause a crash.

The contact owns a 2004 Ford F-150. While driving between 30-50 mph, the front brakes would grind and the brake pedal would pulsate when the brakes were applied. The dealer stated that the pistons in the calipers were misaligned and failed to release the brake rotor. The dealer replaced the rotors and calipers. The current and failure mileages were 27,288.

Failure of rear calipers on 2004 Ford F-150 truck causing tires to lock up or violent shaking in front end.

While traveling on I-10 vehicle vibrated violently. Once while traveling approximately 55 mph and once at 65 mph. During the incidents the vibration was not isolated to one part of the vehicle but the whole vehicle vibrated. After inspecting the vehicle the next day in daylight I noticed the following: 1. All wheel rims were completely covered with brake dust. Even though I had just washed the vehicle prior to starting the 1,000 mile trip from houston, TX to green cove springs, FL. 2. All wheel rims had what was either brake fluid or melted wheel grease on the surface. 3. All four tires were damaged by the vibration I. E. , tread had started to delaminate from the tire. Tires had approximately 28,000 miles at the start of trip and were in good condition with no tire worn to wear bar. 4. All four tires had scuff marks that appeared as if the tires had been run low on air. 5. The front rotors on the outside surface were the brake pad made contact were grooved beyond what should have been present on a vehicle with 29,000 miles on the odometer. Metal shavings were present on the front wheel rims. 6. The rear rotors were also grooved on the outside with the inside appearing as if the brake pad was not making contact with the rotor surface I. E. , only outside pad is making proper contact. I took the 2004 Ford F-150 to the Ford dealer located in green cove springs, FL for correction of the above problems. Service manager initially resisted admitting that anything was wrong with the vehicle until a maintenance tech walked by and said he had a "TSB on that". Dealer subsequently replaced the front rotors, calipers, and pads. However, the service manager would not admit the vibration caused the damage to the tires. The rear calipers, rotors, and pads were not serviced or changed. Further, the service manager could not or would not admit to original problem with the vibration being fixed.

I had to replace my brake rotors and calipers due to corrosion after only 18000 miles, and again after about 35,000 and 60,000 miles due to corrosion. On two occasion, this problem was discovered when the brakes completely locked up and the vehicle could not move. Much of my driving is on snow-covered roads with road salt, but I routinely use a car wash with undercarriage wash frequently -- about once per week. Is there no technology to increase the corrosion resistance of these critical safety parts?.

2004 f150 brakes began to shimmy and shutter 3 months after purchase. Rotors and brakes were resurfaced and replaced. ** answer required*** about three months after the vehicle was purchased the consumer began have problem with the brakes. The dealer has replaced the rotors 3 time, resurfaced them twice, replaced the brake pads three times and replaced the front calipers once. The rear end was replaced on Dec 2, 2004 because of vibration and bad bearings.

The 2004 f150 and I assume expeditions had undersized front brake rotors and calipers and were outlined in a service tech bulletin for the purpose of diagnosing the front end shaking/shimming during braking. This is my opinion should have fallen under a mandatory recall due to the serious nature of poor engineering. No recall and out of pocket $$$. The same holds true for the rear differential which in my case has been replaced (3) times and again Ford published a tech bulletin outlining the fact that the '04 rear differential housing was subject to faulty machining causing rapid wear on ring/pinion and bearings. I believe these two defects should have been addressed due to the fact that failure of either component could result in a serious accidents. I truly believe Ford tried to cover up/white wash these defects. I still have this '04 and still have issues with the brakes and rear differential not to mention a host of other issues that have plagued this particular year model. I look forward to hearing from someone and would like to know the extent of Fords involvement and any accidents involving '04f150's. Best regadrs.

The contact owns a 2004 Ford f150. While driving 60 mph, the vehicle's steering wheel and front end shake. The rack and pinion was replaced at 48,000 miles, the rotors were replaced and turned several times, and the calipers were replaced as well. However, the failure persists. While driving over 40 mph and making a sudden stop, the brake pedal goes all the way down to the floor and the vehicle eventually stops. The brake pedal must continuously be pumped for pressure while driving. The dealer stated that the brakes are normal. The vehicle has been experiencing the failures since the date of purchase. The current mileage is 51,000 and failure mileage was 2,000.