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really awful
Crashes / Fires:
4 / 2
Injuries / Deaths:
1 / 0
Average Mileage:
30,296 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 #15

Nov 082011


  • 73,000 miles


The contact owns a 2004 Ford Expedition. The contact stated that while exiting a parking space and applying the brakes, the brake was depressed into the floorboard abnormally. The contact drove the vehicle to a local mechanic and notice brake fluid leaking. The mechanic advised that the radiator supporter was rusted and also caused the brake lines to rust. The mechanic replaced the radiator support unit and the brake line. The contact called the manufacturer regarding the faulty brake lines and the manufacturer stated there was nothing they could do to assist. The failure mileage was 73,000.

- Cheshier, CT, USA

problem #14

Jan 012011

Expedition 8-cyl

  • Automatic transmission
  • 80,000 miles
The contact owns a 2004 Ford Expedition. The contact was driving 40 mph and changing gears when he attempted to apply the brakes but there was no response. The contact was unable to stop the vehicle and crashed into a pile of snow in order to stop the vehicle. The vehicle was taken to the dealer who was unable to diagnose the failure. The manufacturer was made aware of the failure who referred him back to the dealer. The vehicle was not repaired. The failure mileage was 80,000 and the current mileage was 86,000. Updated 9/13/11

- Alpharetta, GA, USA

problem #13

Apr 172011


  • 98,835 miles
The contact owns a 2004 Ford Expedition. The contact was coming to a stop and depressed the brake pedal when the vehicle would not stop or slow down. The contact crashed into a pole and a gas meter before the vehicle caught on fire. The fire department was called and extinguished the fire and a fire report was filed. No one was injured yet the vehicle was destroyed. The origin of the fire was unknown. The dealer was not contacted. The manufacturer was made aware of the failure who stated that they will send a representative out to inspect the vehicle. The failure mileage was 98,835.

- Houston, TX, USA

problem #12

Apr 242006


  • 10,000 miles


The contact owns a 2004 Ford Expedition. The contact was driving approximately 35 mph when the vehicle began to vibrate while the brake pedal was depressed. The vehicle was taken to an authorized dealer for repairs. The technician turned the rotors and replaced the brake pads. The vehicle was taken to the dealer on a second occasion for the identical failure. The dealer advised the contact that the front rotors needed to be replaced and the rear rotors needed to be resurfaced. The manufacturer was notified which stated that the failure was caused by normal wear and tear. The failure mileage was 10,000. The current mileage was 28,000.

- Hysperia , CA, USA

problem #11

Mar 302010


  • 44,000 miles
We were involved in an accident. Our 2004 Ford Expedition seamed to fail to respond to slamming on the brakes to avoid collision. We rear ended a car, no one hurt. No air bag deployment at all. #0-35 mph speed. Hit car in front of us after he stopped in road for no reason. Major damage to our truck. Should have been fender bender.

- Troy, MI, USA

problem #10

Oct 312007


  • miles
My 2004 Ford Expedition has had a problem since we bought it from the dealer. The advancetrac will engage on dry surfaces and smooth roads. It will happen anytime of year when the road is dry and should have no reason for turning on. I almost crashed October 31 2007, the ABS turned on and I could not steer, I slowly came to a stop in on the wrong side of the road. It was hard to stop while the ABS was still engaged the whole time. I then turned off the advancetrac and I drove right to the dealer and told them to fix it. I have taken this car in many times to phil long Ford they could never get the car to engage for them. It has happened more than I ever want to count. They have replaced a couple of different things but it still has this problem. Thank you for your time!!

- Littleton, CO, USA

problem #9

Jun 222008


  • 88,000 miles


On 6/22, the right wheel bearing assembly failed while traveling ~20 mph. As a result, a fire occurred. I put the fire out in our driveway at home with a water hose. Significant damage occurred to the right wheel assembly, bearing housing, 1/E axle, rotor, caliper, brake pads, emergency brake, etc...luckily, were close to home and were not traveling 70 mph. No other vehicles were involved and there were no injuries as my wife and I were able to get all of our children out of the Expedition safely. Our Expedition is a 2004.

- Moseley, VA, USA

problem #8

Apr 142006

Expedition 6-cyl

  • Automatic transmission
  • miles
Brakes have failed to work properly on several occasions. Three (3) times when I backed up out of my driveway...brakes completely failed...I almost hit the trees across street in my neighbor's yard. I pumped the brakes vigorously when I realized they weren't working. Don't know how I escaped an accident. It happened again when I tried to back up one night when I was away from home in North Carolina. I realized the truck was not going to stop - so I threw the gear shift up into forward drive...barely escaped hitting a gas meter on a house.. this would have been a horrible accident. There were 5 people in the truck and 2 people in the bedroom of the house I almost hit. This brake failure on the 2004 Expedition is a really bad problem. You drive the truck at your own risk. It is an accident - just waiting to happen again. Dealer in North Carolina had no clue as to what was happening. The local dealer has no clue....they only say if it reoccurs while the truck is in their possesion, they might be able to discover what is happening. Is this a potentially dangerous vehicle" what does Ford moter company say about it??? does anyone know"

- Trumann, AR, USA

problem #7

Sep 162006


  • miles
On 9/16/06 at approximately. 64,500 miles on odometer without any similar problem, I started car at los angeles international airport parking lot #3 with foot on brake. Brake pedal went to all the way the floor as engine started and escaping air type sound heard. Pumped pedal and each time it depressed less and less until full brake pedal returned. Drove and applied brake numerous times without incident until reaching intersection of sepulveda blvd. And West slauson avenue (3.34 miles: Per map quest). Entered left turn lane applying brake to stop for red light. At approximately 20 mph brake pedal went to floorboard again. Could not stop and vehicle proceeded through signal. Fortunately oncoming traffic was stopped or there would have been an accident. Pumped pedal several times as vehicle coasted forward and full break pedal returned. Problem hasn't recurred since. Took vehicle to vista Ford, woodland hills. Service tech could not duplicate problem. (I have seen nine similar complaints on this NHTSA site... all referencing the problem as intermittent and all reflecting the Ford dealers service dept. Could not duplicate and could not determine source of problem). This needs to be investigated before someone is seriously injured!!!

- Tarzana, CA, USA

problem #6

Jun 122005

Expedition 8-cyl

  • Automatic transmission
  • 30,400 miles
Air bag/brakes failed. 2004 Ford Expedition. At 28500 miles brakes and rotor was replaced along with the clutches in the rear two weeks later this accident. Noise was still heard in the rear after the repair. Car was totaled.

- Eads, TN, USA

problem #5

Aug 012005

Expedition 8-cyl

  • Automatic transmission
  • 8,000 miles


During emergency stop it was noted that the brake pedal went to the floor. SUV had less then 8K miles on it. Dealer turned the disks and replaced pads and bled brake system. Brakes still go to the floor and now have brake shudder at 13K miles.

- Vacaville, CA, USA

problem #4

Oct 112004

Expedition 8-cyl

  • Automatic transmission
  • 20,000 miles
On three occasions the brakes on my 04 Expedition failed. Twice was when towing a 5000 lb. Trailer, and I assumed the problem was connected with that. But the other day when not towing I almost clobbered the car ahead of me when I had to make a hard stop. On the three occasions the pedal goes almost to the floor with little (but some) braking effect. The Ford garage cannot find anything wrong.

- Tallahassee, FL, USA

problem #3

Mar 032004

Expedition 4WD 8-cyl

  • Automatic transmission
  • 200 miles
I purchased a new 2004 Ford Expedition the front brakes give off huge amounts of brake dust in 100 miles the rims are solid black. I feel this is a safety issue and may result in brake failure.

- Islip, NY, USA

problem #2

Mar 142004


  • Automatic transmission
  • 2,000 miles
While driving 45 mph brakes failed. Driver pressed the brake pedal, which pulsated and went down to the floor. Somehow vehicle stopped without incident. After the vehicle stopped engine check warning indicator illuminated. The dealer was not sure how to repair this problem.

- Canandaigua, NY, USA

problem #1

Jan 282004

(reported on)

Expedition 8-cyl

  • Automatic transmission
  • miles
Excessive accumulation of brake dust was found on the aluminum wheels. There' is tsb 10004901 on this issue, and the manufacturer has a kit that the consumer can purchase for $230 plus installation. The kit is not guaranteed to correct the problem, but it will reduce the dust accumulation, per the dealership.

- Wellington, FL, USA

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