2002 Ford Excursion Brakes Problems

TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT WHILE TRAVELING 55 MPH AND APPLYING THE BRAKES, THERE WAS AN ABNORMAL NOISE HEARD FROM THE BRAKING SYSTEM. THE BRAKE PEDAL BECAME STUCK AND THE VEHICLE WOULD NOT SLOW DOWN. THE CONTACT CONTINUED TO PUMP THE BRAKES AND WAS ABLE TO COAST TO A STOP. THE CONTACT LATER PARKED THE VEHICLE AND NOTICED THAT A FIRE HAD STARTED FROM UNDER THE VEHICLE. THE CONTACT WAS ABLE TO EXTINGUISH THE FIRE HOWEVER, THE TRANSMISSION AND CENTRAL COMPUTER WAS DESTROYED. THE VEHICLE WAS TOWED TO A DEALER WHERE THE TRANSMISSION COMPUTER MODULE, TRANSMISSION AND THE BRAKE BOOSTER WAS REPLACED. THE DEALER ADVISED THAT THE BRAKE BOOSTER LEAKED ONTO THE TRANSMISSION AND THE FRONT DRIVE SHAFT, CAUSING THE VEHICLE TO CATCH ON FIRE. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO THE DEALER THREE WEEKS PRIOR TO FIRE AND THERE WAS NO INDICATION OF A POTENTIAL FAILURE. THE FAILURE MILEAGE WAS UNKNOWN. THE CURRENT MILEAGE WAS 190,000.

NHTSA ID

10496815

Incident

Aug 6, 2012

I OWN A 2002 EXCURSION. NEVER IN WATER OR AN ACCIDENT.85,000 MILES ONLY SERVICED BY FORD,LINCOLN DEALERSHIPS. LOST 'BRAKES'. BRAKES WENT TO THE FLOOR. IT TURNS OUT ALL THE BRAKE FLUID LINES (NOT THE HOSES) AND THE FUEL LINE IS 'ROTTED' OUT. CALLED FORD, CASE#[XXX] . DECLINED TO DO ANYTHING BECAUSE VEHICLE OUT OF 6 YEAR WARRANTY. DEALERSHIP SAID 'THIS NEVER SHOULD HAVE HAPPENED'. WE NEED HELP, COST OF REPLACING ALL CLOSE TO $2000.I AM THE ORIGINAL OWNER. CAN YOU HELP? WE HAVE A 2001 FORD VAN, 175,000 MILES. ALL THE LINES ARE LIKE BRAND NEW. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10343242

Incident

Jul 7, 2010

Mileage

85,000 mi

I SEEM TO BE HAVING A BRAKING PROBLEM WITH MY 2002 FORD EXCURSION. I HAVE HAD TO REPLACE BRAKE PADS AND ROTORS ON A NUMBER OF INSTANCES. IT SEEM TO BE CAUSED BY THE BRAKE CALIPER SLIDE BRACKETS WHICH PREVENT THE PROPER CALIPER TRAVEL WHEN ACTIVATED. THIS WAS A COMPLAINT I HAVE ADDRESSED SINCE MY PURCHASE OF THE VEHICLE. THE PROBLEM GIVES THE VEHICLE AN UNEVEN BRAKE ACTIVATION, WHICH CAUSES POOR HANDLING WHILE BRAKING. THE DEALER SAY THAT IT IS NOT A WARRANTY ISSUE. THE DEALER HAS REPLACED 2 CALIPERS, BUT EACH TIME I'M EXPECTED TO PAY FOR PADS AND ROTORS. I'M AN EX GARAGE OWNER, AND EX-NYS VEHICLE INSPECTION LICENSED MECHANIC. I HAVE ON 5-6 INSTANCES REPLACED PADS AND ROTORS DUE TO THIS PROBLEM WITH THE CALIPER SLIDE SYSTEM. EACH OF THESE TIMES, AFTER PULLING THE BRAKES APART, AND CLEANING ALL SURFACES, AND LUBING THE SLIDERS BEFORE REINSTALLING, AFTER WITCH ALL PARTS WORKED AS DESIGNED. THIS ONLY SEEM TO GET YOU TO ANOTHER 2000 TO 3000 MILES BEFORE IT IS REQUIRED AGAIN. IN MOST CASES COSTING ME ANOTHER SET OF BRAKE PADS, AND ALSO AT LEAST ONE NEW ROTOR. THIS SITUATION HAS BEEN SEVERE ON 2 OCCASIONS, WHILE 30 MILES OR MORE FROM HOME, EACH TIME, THE CALIPER STUCK, AND GROUND INTO THE ROTOR. AS I DROVE THE VEHICLE, THE BRAKE PAD PULLED FROM ITS PROPER LOCATION, AND FELL OUT, LEAVING ME WITH NO BRAKES AT ALL. THIS WAS ON THE REAR OF THE VEHICLE. I HAD TO BE TOWED. I THINK THIS BRAKE SYSTEM NEEDS TO BE REVIEWED, AND DON'T THINK A BRAKE SYSTEM SHOULD NEED TO BE ADDRESSED WITH EVERY 2000 MILES OR SO. *TR

NHTSA ID

10297795

Incident

Dec 15, 2009

Mileage

44,285 mi

LOST CONTROL OF VEHICLE RESULTING IN ROLLOVER CRASH. EXACT DEFECT UNCERTAIN (HAPPENED VERY QUICKLY) BUT PROBABLY RIGHT REAR WHEEL LOCKED WITH INABILITY TO STEER VEHICLE AS RESULT. ALSO, SEVERAL MONTH HISTORY OF DIFFICULTY WITH BRAKES FOR MONTHS WITH IDENTIFIABLE CAUSE DESPITE 4 VISITS TO FORD MECHANICS. *JB

NHTSA ID

10158310

Incident

May 1, 2006

BRAKE ROTORS WARP EXCESSIVELY. JUST PURCHASED USED VEHICLE, HAD TO HAVE THE ROTORS TURNED AND BRAKE SYSTEM SERVICED AFTER 5,000 MILES. VEHICLE WOULD VIBRATE EXCESSIVELY UPON APPLICATION OF BRAKE. FORD SERVICE REPRESENTATIVES THAT INSPECTED THE BRAKE SYSTEM STATED THAT THE PADS LOOKED ALMOST NEW. IN DOING RESEARCH ON THE INTERNET THIS EXACT SCENARIO SEEMS TO BE PLAYING OUT WITH 2000 - 2004 EXCURSION MODELS. OTHER OWNERS CLAIM TO HAVE THE BRAKE SERVICED AND ROTORS TURNED EVERY 15000 - 25000 MILES. IT SEEMS THAT THE ROTORS ARE NOT ADEQUATE TO HANDLE THE WEIGHT OF THE VEHICLE WITH OUT NEEDING EXCESSIVE SERVICE ON A FREQUENT BASIS. *NM

NHTSA ID

10149994

Incident

Feb 10, 2006

Mileage

54,890 mi

MY PROBLEM IS THE TRUCK HAS WARPED 4 SETS OF FRONT ROTORS IN 80,000 MILES. IT HAS YET TO EVEN WEAR THE REAR ROTORS. EACH TIME IT HAS WARPED THE ROTORS THE PADS WERE REPLACED. THE FIRST 2 SETS OF ROTORS WERE FROM FORD. I THEN PURCHASED HIGH PERFORMANCE SLOTTED ROTOR WITH SPECIAL PADS. THIS MADE NO DIFFERENCE TO THE WARPING PROBLEM. I HAVE TALKED TO OTHER OWNERS OF EXCURSIONS AND THEY ARE HAVING THE SAME PROBLEM. FORD SAYS (DEALER & FACTORY REP) THIS IS NORMAL WEAR. MY EMPLOYMENT PUTS ME ON THE ROAD APPROXIMATELY 6 TO 8 HOURS PER DAY. I HAVE OWNED A FORD BRONCO FULL SIZE, FORD F150 FULL SIZE, DODGE RAM 2500, NISSAN, PLUS SEVERAL CARS. THIS IS THE ONLY TIME THAT I HAVE EVER HAD A WARPING PROBLEM. I FEEL THE EXCURSION IS PUTTING TOO MUCH PRESSURE ON THE FRONT BRAKES AND/OR NOT MUCH ON THE REAR. THIS SEEMS TO MAKE THE TRUCK HARDER TO STOP IN QUICK STOPS - THUS MAY CAUSE ME TO HAVE AN ACCIDENT DUE TO INABILITY TO STOP IN TIME.

NHTSA ID

10127413

Incident

Jul 4, 2005

WHILE APPLYING THE BRAKE PEDAL, THE VEHICLE JERKED AND VIBRATED UNCONTROLLABLY. HOWEVER, THE DRIVER WAS ABLE TO MAINTAIN CONTROL OF THE VEHICLE AND DROVE IT TO THE DEALER FOR INSPECTION. THE MECHANIC INFORMED THE DRIVER THAT THE ROTORS NEEDED TO BE REPLACED. PLEASE PROVIDE FURTHER DETAILS. *JB *BF *NM

NHTSA ID

10096649

Incident

May 10, 2004

Mileage

54,000 mi

AFTER PURCHASING A USED VEHICLE FROM INTERNET AUTO SALES IN RENO, NEVADA, THE BRAKES WERE NOT WORKING CORRECTLY. THE BRAKES PULLED THE VEHICLE VIOLENTLY TO THE RIGHT. THE DEALER REPLACED THE CALIPERS AND PADS AND TURNED THE ROTORS AND TOLD ME THE PROBLEM WAS SOLVED. AFTER TEST DRIVING THE VEHICLE, THE BRAKES HAD THE SAME PROBLEM. THE VEHCILE WAS SENT TO THE LOCAL LITHIA DEALER AND THEY ENDED UPREPLACING THE ABS SENSOR ONCE. AFTER THAT THE VEHCILE DID NOT IMPROVE. SO, THE VEHCILE WENT BACK TO THE DEALER AND THE DEALER TOOK THE BRAKE SYSTEM APART AND COULD NOT FIND ANYTHING WRONG WITH IT. THEY RETURNED THE VEHICLE AND SOON AS I DROVE IT, THE BRAKES FAILED TO OPERATE CORRECTLY. THEY TOOK THE VEHCILE BACK AND THEY REPLACED SOME MORE BRAKE PARTS, BUT IT DID NOT SOLVE THE PROBLE,. IN FACT, THE PROBLEM GOT WORSE. NOW, THE BRAKES ARE PULLING BOTH LEFT AND RIGHT. THERE IS NO RHYME OR EASON AS TO WHY IT WILL PULL ONE WAY OR THE OTHER. THE VEHICLE IS UNSAFE AND I HAVE ASKED THE DEALER TO PURCHASE THE VEHICLE BACK BECAUSE IT IS A LEMON, BUT THEY REFUSE TO BUY THE VEHICLE BACK. MY ONLY OPTION IS TO CONTINUE TO TAKE IT BACK TO THE DEALER AND HOPEFULLY, THEY WILL REPLACE EVERYTHING SO THAT THE BRAKES WILL WORK CORRECTLY. THIS IS THE SAME PROBLEM I AM HAVING WITH MY FORD F-350 SUPER DUTY.*AK

NHTSA ID

10086758

Incident

May 7, 2004

Mileage

42,700 mi

I STARTED EXPERIENCING VIBRATING IN MY STEERING WHEEL DURING BRAKING SEVERAL MONTHS AGO. THE VIBRATION CONTINUED TO GET WORSE. I HAD THE BRAKES CHECKED AND I FOUND OUT THAT ALL FOUR ROTORS WERE WARPED ON THE VEHICLE. THE VEHICLE ONLY HAS 27000 MILES ON IT AND THE BRAKE PADS ARE IN EXCELLENT CONDITION. THROUGH RESEARCH I FOUND THAT MANY OTHER PEOPLE HAVE HAD ROTOR PROBLEMS AT A VERY EARLY STAGE ON THEIR FORD EXCURSIONS. FORD REFUSES TO ACKNOWLEDGE A PROBLEM WITH THE ROTORS OR REPAIR THE PROBLEM AT THEIR COST.*AK

NHTSA ID

10078547

Incident

May 27, 2004

Mileage

26,500 mi

WHILE DRIVING AT A SLOW SPEED A CAR MADE A SUDDEN STOP IN FRONT OF NO MATTER HOW HARD I STEP ON THE BRAKES THE TRUCK DID NOT STOP.*AK

NHTSA ID

10059103

Incident

Feb 21, 2003

Mileage

33,100 mi

WHILE DRIVING, THE VEHICLE JERKED AND THE ABS LIGHT ILLUMINATED. ALSO WHEN BRAKING, THE VEHICLE WENT TO THE RIGHT. *AK *JB

NHTSA ID

10057749

Mileage

30,000 mi

ON 8-25-03 , I TOOK MY 2002 FORD EXCURSION IN TO BERRYVILLE FORD IN BERRYVILLE ARKANSAS BECAUSE THE VEHICLE WOULD NOT STOP IN A REASONABLE DISTANCE. IF YOU ARE GOING DOWNHILL AND YOU HAVE TO BRAKE SUDDENLY AND HARD THE BRAKES GET HOT AND YOU LOSE THEM ALLTOGETHER.THIS VEHICLE HAS ONLY 27,774 MILES. IT HAS BEEN IN THE SHOP THREE DIFFERENT TIMES AND THET R&R THE BRAKE BOOSTER THEY R&R THE HYDRAULIC CONTROL UNIT . THE BRAKE SHOES HAVE BEEN REPLACED TWICE THE ROTORS HAVE BEEN RESURFACED AND THIS VEHICLE WILL NOT STOP . IF YOU BRAKE MORE THAN THREE TIOMES THE BRAKES WILL OVERHEAT AND THEN YOU CANNOT STOP AT ALL. I FEEL THIS VEHICLE IS UNSAFE TO DRIVE. IT IS CURRENTLY SITTING IN THE YARD AT THE BERRYVILLE DEALERSHIP. THE DEALERSHIP CANNOT GET AUTHORIZATION FROM FORD TO CHANGE THE ROTORS . THIS VEHICLE WAS PURCHASED AT BERRYVILLE FORD AND I WAS TOLD BY THE SERVICE MANAGER AND THE DEALERSHIP MANAGER OFF THE RECORD TO TAKE IT SOMEWHERE ELSE. THEY DON"T KNOW WHAT IS WRONG. THE ENGINE IS A V-10 AT 20MPH YOU MAY GET IT STOPPED BUT IF YOU HAVE A PANIC STOP IT WILL NOT STOP.

NHTSA ID

10039561

Incident

Aug 25, 2003

Mileage

26,000 mi

FRONT ROTORS RUSTED IN CENTER AREA BETWEEN ROTOR BRAKE SURFACE. AT 30,000 MILES MY 2002 FORD EXCURSION STARTED TO SHAKE VIOLENTLY WHEN BRAKING AT SPEEDS ABOVE 40 MPH. LUCK FOR US WE WERE DRIVING IN LOWER SPEED CONDITIONS IN RESIDENTIAL TRAFFIC. I INSPECTED THE BRAKE PADS AND ROTORS FOR PROBLEMS AND FOUND LARGE AMOUNTS OF RUST DECAY IN THE ROTORS CAUSING THE WARPING TO THE ROTORS. I HAVE SERVICED THE BRAKE SYSTEM AND REPLACED THE FRONT ROTORS AND PADS WITH EXCELLENT RESULTS. I HAVE KEPT THESE ROTORS IF ANY ONE SHOULD LIKE TO FURTHER LOOK INTO THIS SITUATION. WE LIVE IN THE DESERT WITH VERY LOW RAIN OR SNOW. NOW SALTS ARE USED IN MY HOME AREA. I HAVE NEVER SEEN SUCH CORROSION TO AND IMPORTANT SAFETY SYSTEM. IF THIS IS A PROBLEM THAT COULD CAUSE HARM TO OTHERS I WOULD LIKE TO GET THE WORD OUT. I REGULARLY RESPOND TO ACCIDENTS AND VEHICLE EQUIPMENT FAILURES AS FIREFIGHTER/MEDIC. REGARDLESS OF FAULT IT IS A PROFESSIONAL DUTY TO AT LEAST MAKE THIS NOTIFICATION. *JB

NHTSA ID

10039262

Incident

Sep 18, 2003

Mileage

31,189 mi

2002 FORD EXCURSION. TWO INSTANCE OF THE VEHICLE NOT RESPONDING TO PRESSURE APPLIED TO THE BRAKE PEDAL AT LOW SPEED. VEHICLE CONTINUES TO ROLL WITH VERY LITTLE STOPPING ACTION. TAKEN TO DEALERSHIP WHERE NOTHING WAS FOUND. *NLM

NHTSA ID

10018824

Incident

Jan 15, 2003

Mileage

31,000 mi

THE VEHICLE HAS A FRONT SUSPENSION PROBLEM WHICH CAUSES THE VEHICLE TO VIBRATE, THE VEHICLE HAS BEEN TO THE DEALER 3 TIMES BUT THE PROBLEM STILL EXIST, BOTH DRIVER SIDE DOORS ARE MISALIGNED WITH RESPECT TO THE FENDER TRIM, THE DIFFERENTIAL WAS ORIGINALLY MISALIGNED WITH RESPECT TO THE REAR FENDER TRIMS, NOW THE DIFFERENTIAL IS PROPERLY ALIGNED AND THE CONSUMER QUESTIONED THE TECHNICIANS WHO STATED THAT THEY DID NOTHING TO CORRECT THE MISALIGNMENT, THE CONSUMER FEELS THIS IS A DEFINITE SAFETY PROBLEM IF THE DIFFERENTIAL GOES IN AND OUT OF ALIGNMENT ON IS OWN, THE A/C WAS NOT COOLING AND NEEDED TO BE RECHARGED, THE CONSUMER CAN HEAR STATIC IN RADIO WHEN TURNING ON THE REAR TV SWITCH, A/C AND TURN SIGNAL, STEERING GEAR AND HYDRO BOOST LINE REPLACED, TIRE OUT OF BALANCED CAUSING VIBRATION AT 75-70 MPH, STEERING OUT OF ADJUSTMENT (OFF CENTER), CALIPERS REPLACED, TRANSMISSION EXPERIENCING A DELAY WHEN SHIFTING, BOTH WIPER BLADES OFF CENTER, DRAIN PLUG LEAKING OIL, WEATHER STRIPPING ON RIGHT REAR DOOR FAILED, HEADLINER IS COMING LOOSE ON THE LEFT SIDE, WINDSHIELD WASHERS INOPERATIVE, FUEL GAUGE READ INCORRECTLY, FAULTY ACCELERATOR PEDAL CAUSED THE VEHICLE TO STALL WHEN COMING TO A STOP. NLM

NHTSA ID

568342

Incident

Aug 26, 2002

WHILE APPLYING BRAKES VEHICLE WILL NOT STOP. CONSUMER WILL SHIFT VEHICLE IN PARK TO COME TO A COMPLETE STOP. DEALERSHIP SHIP IS AWARE OF PROBLEM.*AK

NHTSA ID

8015006

Incident

Apr 1, 2002

VEHICLE WAS BACKED INTO DRIVEWAY, PARKED WITH ENGINE OFF. DRIVER INTENDED TO RELOCATE VEHICLE ABOUT 6 FEET FORWARD, NEVER ENTER STREET. DRIVER STARTED ENGINE, AND WITH RIGHT FOOT ON BRAKE PEDAL PLACED TRANSMISSION IN DRIVE. DRIVER RELEASED BRAKE PEDAL AND ALLOWED VEHICLE TO MOVE FORWARD TO INTENDED PARKING SPOT WHERE HE APPLIED THE BRAKES WITH THE RIGHT FOOT. THE VEHICLE DID NOT STOP, DRIVER PLACED BOTH FEET ON THE BRAKE PEDAL BUT VEHICLE STILL WOULD NOT STOP, ROLLED INTO THE STREET AND STRUCK A PASSING VEHICLE. VEHICLE WAS TOWED TO DEALER, BUT DEALER COULD NOT FIND ANYTHING WRONG. FORD CONSUMER APPEALS BOARD WAS CONTACTED, BUT AGREED WITH THE DEALER. VEHICLE OWNER CONTACTED A PRIVATE MECHANIC AND WAS TOLD THAT THE MOST LIKELY FAILURE THAT COULD CAUSE THE SYMPTOMS EXPERIENCED WAS THE POWER BOOSTER UNIT. VEHICLE WAS TOWED TO INSURANCE COMPANY LOT WHERE IT WILL BE EXAMINED FOR POSSIBLE SUBROGATION WITH THE MANUFACTURER. OWNER HAS PICTURES OF THE DRIVEWAY AND SIDEWALK SHOWING TIRE MARKS LEADING RIGHT TO THE CRASH SITE.*AK

NHTSA ID

764082

Incident

Jun 22, 2002