BRAKE SHUDDER (ROTOR THICKNESS VARIATION) DUE TO THE NEW LOW DUST FRONT BRAKE LINING USED IN PRODUCTION, OR NEW LININGS THAT WERE INSTALLED PER TSB 04-05-02.
full bulletin at NHTSA ↗2005 Ford Expedition brakes problems
severe Owners of the 2005 Ford Expedition have filed 13 NHTSA complaints about the brakes, typically surfacing around 59,500 miles at roughly $450 to repair (U.S. federal records, as of August 2026). Source: NHTSA Office of Defects Investigation. See brakes across all vehicles →
Failure mileage
Complaints
13
Recalls
0
Avg fix
$450
| Model year | brakes complaints |
|---|---|
| 2005 Expedition (this page) | 13 |
| 2006 Expedition | 12 |
| 2007 Expedition | 22 |
| 2008 Expedition | 27 |
| 2009 Expedition | 3 |
3crashes
1injury
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering brakes on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
BRAKE SHUDDER.
full bulletin at NHTSA ↗UNINTENDED BRAKE ASSIST.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2005 Ford Expeditions report four distinct brake-system problems.
Rusted brake lines: Multiple owners experienced complete brake failure when brake lines corroded through in the undercarriage, particularly between the passenger-side front tire and the ABS box. One owner doing 25 mph lost all four brakes and had to use the parking brake to stop. Another with 67,000 miles noted extensive rust on brake lines throughout the front. Owners report the tandem master-cylinder backup did not prevent total failure, and one notes his mechanic sees this "all the time" on Ford vehicles.
Brake booster failure: One owner experienced complete brake failure one day after the truck passed a 60,000-mile service. The Ford dealer initially diagnosed a failed brake booster but later changed the report to "undetermined" after consulting Ford's Office of General Counsel.
Intermittent soft brake pedal: One owner had front calipers and rotors serviced in August 2006, but the problem recurred in February 2007 with the pedal going soft and the vehicle groaning and shuddering during low-speed braking. Pumping the pedal restored temporary function, but the issue repeated over several days. The dealer's full diagnostic found "no problems."
Brake and accelerator pedal interference: Owners, including one 6'3" driver with size 11.5 shoes, report the brake and accelerator pedals are positioned too close. Pivoting the foot to brake also depresses the accelerator. One collision resulted when the driver, unaware of the pedal conflict, thought he had slammed the brakes but had actually been accelerating. Dealers refused to address the issue, stating it was "the way the pedals were set up."
Same Ford Expedition brakes reports on nearby years: 2006 · 2007 · 2008
Failure modes owners describe
Rusted brake lines with complete fluid loss
Brake lines corrode through, causing total loss of brake fluid and complete brake failure affecting all four wheels. Occurs in the undercarriage between the passenger-side front tire and ABS distribution box.
When: Various mileages; one at 183,797 miles; one owner with 67,000 miles over 8 years; one incident after a 60,000-mile service
Symptoms owners cite: Complete brake failure with no warning; Low brake fluid warning light activation; Brake pedal goes soft or to the floor; Visible rust on brake lines and frame components; Multiple brake line locations heavily rusted and leaking
Repairs/costs cited: One owner reported a licensed mechanic diagnosed rusted-through brake line; another had brake line replacement performed. Costs not specified by owners.
Recalls/TSBs owners mention: No recalls or manufacturer responses mentioned in narratives.
Brake booster failure
Brake booster ceases to function, resulting in brake failure. Occurred within days of a 60,000-mile service.
When: At 60,000 miles (one reported case on Sept. 17 after 60,000-mile service on Sept. 16)
Symptoms owners cite: Complete brake failure without warning; Inability to stop the vehicle despite pushing the brake pedal
Repairs/costs cited: Ford dealer diagnosed brake booster failure. Dealer later changed diagnostic report to 'undetermined' after speaking with Ford's Office of General Counsel.
Recalls/TSBs owners mention: No formal recall or TSB mentioned; dealer initially identified booster failure but then reversed the diagnostic determination.
Intermittent soft brake pedal with loss of stopping ability
Brake pedal loses firmness intermittently at low speeds; pedal goes soft and braking effectiveness is lost. Pumping the pedal restores temporary function, but the problem recurs.
When: August 2006 initial complaint; recurrence Feb. 14-18, 2007; another unspecified timing
Symptoms owners cite: Soft brake pedal; Loss of braking effectiveness requiring pump pedal action; Vehicle groans and shudders during braking; Problem occurs repeatedly over several days
Repairs/costs cited: Front brake calipers replaced and front rotors machined at Ford dealer in August 2006. Subsequent dealer diagnostic testing found vehicle free of problems despite recurrence of symptoms.
Recalls/TSBs owners mention: No recall or TSB mentioned.
Brake and accelerator pedal interference
Brake and accelerator pedals are positioned too close together. When a driver's foot pivots to press the brake, the accelerator pedal also gets depressed, causing unwanted acceleration while braking is being attempted.
When: Immediate and recurring upon braking action; one incident led to a collision less than 2 weeks after purchase; problem noted on 4 different occasions
Symptoms owners cite: Simultaneous depression of brake and accelerator pedals; Unexpected acceleration when trying to brake; Vehicle does not decelerate as expected; Problem more apparent in drivers with larger shoe sizes (one owner reported 11.5 inch shoe size and 6'3" height)
Repairs/costs cited: Dealer stated this was the way the pedals were designed and could not be fixed. No repairs performed.
Recalls/TSBs owners mention: Dealers informed owners there is no recall and will not assist with the issue.
Synthesized from 13 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had brakes trouble with your 2005 Ford Expedition?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the brakes problem on the 2005 Ford Expedition?
It's a meaningful issue. 13 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $450.
At what mileage does the brakes typically fail?
Across the 9 complaints that reported odometer mileage, most brakes failures cluster between 53,092 and 123,000 miles, with the median around 59,500. A quarter of owners report trouble before 53,092; a quarter make it past 123,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $450 for brakes repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to brakes?
No active recalls currently cover brakes issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Ford/Expedition.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.