Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

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hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
103,687 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Ford Expedition brakes problems

brakes problem

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2004 Ford Expedition Owner Comments

problem #5

Sep 252016


  • 107,000 miles


The contact owns a 2004 Ford Expedition. While independently performing routine service on the vehicle, the contact noticed that the brake line was corroded. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the issue. The failure mileage was 107,000.

- Massapequa, NY, USA

problem #4

Sep 242016


  • 160,000 miles
Brake line failure due to rust. Cars previously had dual hydraulic systems. If one failed, the other still worked. That is no longer true. It's all one hydraulic system and if a leak occurs, there is no secondary system; only the emergency brake is available to stop the vehicle. And now, in new cars, the emergency brake has switched to electric. Previously you could gradually apply the manual emergency brake to slow down after a hydraulic failure, but no more. I have now had 2 rust induced brake line failures in my 2004 Ford Expedition, and thankfully, a working emergency brake was able to stop the vehicle before a major accident occurred. New cars no longer have this same luxury of an emergency brake. They have only the electric parking brake - no graduated controls, no manual intervention. And the new auto braking systems are great to prevent rear end collisions, but only when the hydraulic pressure is working. You need to consider bringing back the dual hydraulic system and the manual (gradually) emergency brake.

- Apex, NC, USA

problem #3

May 092015


  • 141,433 miles
Experienced a near complete brake failure due to sudden loss of brake fluid. I was able to make it home as the incident occurred on an interstate within a mile of my residence. Cavalier Ford at chesapeake sq. Had just done "the works" package oil change just 2 hours earlier and reported that brake lines were checked and everything was "green." I had the vehicle towed back to cavalier Ford and the service manager reported to me that my brake line was rusted through near the front axle. The vehicle has been kept and maintained in chesapeake, va and I am the original owner. The service desk was very surprised because there is little road salt conditions in this area during winter.

- Chesapeake, VA, USA

problem #2

Feb 272014

Expedition 8-cyl

  • 110,000 miles
I was driving up to a traffic light, in my 2004 Expedition. Coming to a stop. A good thing, I was not driving to fast, or had to make a sudden stop quickly. There was not a vehicle in front of me, thanks to god! had my foot on the brakes, and the pedal went down to the floorboard. Now I have no brakes at all. The indicated lights, for brake fluid came on. So, I stop to refill brake fluid. There, I notice a busted brake line. I have only seeing this in the movies, I have been driving for 30 now. I could have lost my life, or taken someone else life. After looking online. I have seeing, others with some of the same problem, with the 2004 Expedition. But there no recalls, and I know Ford motor have heard of this, and others too, that is the place to do something for the safety of the people(small). But nothing is being done!

- Hopemills , NC, USA

problem #1

Jul 052013


  • miles
Was driving when brakes went completely out when I went to stop at a stop sign.. cause due to rust corrosion. Brakes giving out could have caused a fatal car accident. Rust has damaged all brake lines and fuel lines. Rust is now moving up the vehicle. Brake lines and fuel lines should have a protected coating or made with a non corrosion metal. I had no idea that my brake line was rusted out till my brakes gave out. These vehicle need to be recalled and have new lines. Also have a protected coating applied under the vehicle to stop rust. Very very dangerous driving around not knowing that you have rust under your vehicle eating away at your brake lines and fuel lines.

- Pass Christian , MS, USA

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