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 ↗2006 Ford Expedition brakes problems
severe 12 complaints filed with NHTSA · avg repair $450 · see brakes across all vehicles →
Failure mileage
Complaints
12
Recalls
0
Avg fix
$450
3crashes
4injuries
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 describe a range of brake failures in 2006 Expeditions, with the most critical being sudden, complete loss of braking power. Multiple complaints detail the brake pedal going to the floor with no resistance, resulting in inability to stop at highway and city speeds—two owners were in crashes as a result. At 13,000 and later at 19,783 miles, one owner experienced repeated brake failure: the first caused a collision with injury and airbag deployment; a second failure occurred a month after a $2,300 repair that included replacing most of the braking system.
A second failure mode involves soft, spongy pedal feel with increased pedal travel before engagement. One owner describes needing to "stand on the brakes" to achieve stopping power, despite dealer service and a Ford TSB for front caliper, rotor, and pad replacement. The system improved temporarily after manual bleeding but never returned to normal.
Brake line corrosion is reported as causing rupture and complete fluid loss—one owner observed a large puddle under the vehicle, heard only air when pressing the pedal, and had to use the parking brake to stop. Another owner noted visible rust on brake lines at 66,710 miles; the dealer blamed corrosion damage as non-warranty.
The ABS system itself is implicated in at least one failure where brakes grabbed and then released completely on a dry road, leaving the driver without control and resulting in a collision. One owner reports the system fails along with traction control and 4WD simultaneously, though no incident has occurred yet.
Same Ford Expedition brakes reports on nearby years: 2005 · 2007 · 2008
Failure modes owners describe
Brake pedal extends to floor / total brake loss
Brake pedal travels fully to floor, resulting in partial or complete loss of braking power. Multiple owners report sudden inability to stop the vehicle, leading to crashes.
When: 13,000 to 66,710 miles; incidents spanning 2006-2007
Symptoms owners cite: Brake pedal goes to floor with no resistance; Vehicle unable to stop or severely reduced stopping ability; Multiple crashes resulting from brake failure; No warning or gradual fade
Repairs/costs cited: One owner cited $2,300 in repairs including replacement of most of braking system; brake master cylinder replacement reported in another case
Recalls/TSBs owners mention: Dealer claims computer shows no fault codes; one case attributed to rusted brake lines; no recall issued; TSB for caliper/rotor replacement issued (complaint #6)
Spongy / soft brake pedal with increased travel
Brake pedal feels soft or spongy with increased travel before brakes engage. Vehicle does not stop as effectively as before. May be accompanied by brake fluid leakage.
When: Present from purchase; ongoing through 2007
Symptoms owners cite: Spongy brake pedal sensation; Increased pedal travel before brakes engage; Reduced braking effectiveness compared to normal; Brake fluid leakage; Owner reports needing to stand hard on pedal to stop vehicle
Repairs/costs cited: Manual bleeding of brake system provided temporary improvement; dealer replaced front calipers, rotors, and pads per TSB but did not resolve issue
Recalls/TSBs owners mention: TSB issued for front caliper/rotor and pad replacement; dealer claimed larger piston in new calipers explains increased pedal travel as normal operation
Brake rotor vibration and premature wear
Front rotors develop vibration during braking. Initial turning provides only temporary relief; rotors and calipers require replacement, but repairs fail to restore original brake feel.
When: Not specified, but occurring within warranty period
Symptoms owners cite: Vibration when braking; Brake performance does not return to normal after repair
Repairs/costs cited: Dealer turned rotors initially, then replaced rotors and calipers; system bled manually in follow-up service
Recalls/TSBs owners mention: TSB issued for caliper/rotor replacement
Brake line corrosion and rupture
Steel brake lines develop external rust and corrosion, eventually rupturing and causing brake fluid leakage. Leads to total loss of braking power.
When: 66,710 miles reported in one case; dealer noted condition from original ownership (Dec 2006 observation)
Symptoms owners cite: Visible rust on brake lines; Brake fluid puddle under vehicle; Loss of braking power coinciding with fluid loss; Pedal goes to floor with air in lines
Repairs/costs cited: Large puddle of brake fluid under vehicle in one case; brake lines require replacement
Recalls/TSBs owners mention: Dealer initially refused to replace brake lines under warranty without proof of leakage; Ford stated corrosion damage is not covered; owner noted this contradicts safety concern
Brake master cylinder failure
Brake master cylinder fails, resulting in loss of braking power and fluid leakage. Vehicle interior and engine compartment smell of burning.
When: Not specified
Symptoms owners cite: Brake pedal goes to floor with minimal resistance; Burning smell from engine compartment; Front tires extremely hot; Brake fluid loss
Repairs/costs cited: Brake master cylinder replacement required
ABS system malfunction causing brake grab and loss of control
Antilock braking system engages inappropriately, grabbing brakes and then releasing them completely, leaving owner with no control. Occurs on dry roads at moderate speeds.
When: At 35 mph during normal driving
Symptoms owners cite: Brakes grab suddenly; ABS system then releases brakes completely; Pedal goes to floor; No skid marks, indicating no actual wheel lockup; Crash resulted with $21,000 in damage
Repairs/costs cited: $21,000 damage to front end from single-vehicle crash
ABS / traction control system locks brakes on ice
Advanced track braking system locks up brakes while driving on ice at various speeds, causing unsafe deceleration.
When: During winter driving on icy roads
Symptoms owners cite: Brakes lock up on ice
Recalls/TSBs owners mention: Manufacturer stated this behavior is how the advanced track braking system is designed to function
Combined system failure: traction control, ABS, and 4WD
Traction control, ABS, and 4-wheel drive systems all fail simultaneously.
When: Timing not specified
Symptoms owners cite: Traction control fails; ABS fails; 4-wheel drive fails
Synthesized from 12 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 2006 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 2006 Ford Expedition?
It's a meaningful issue. 12 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 11 complaints that reported odometer mileage, most brakes failures cluster between 13,000 and 59,851 miles, with the median around 36,700. A quarter of owners report trouble before 13,000; a quarter make it past 59,851. 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/2006/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.