Twenty-seven complaints describe a 2008 Ford Expedition with a brake system prone to failure across multiple modes. The most severe incidents involve complete brake loss at highway speeds or in emergency stops—owners report standing on the pedal with no response, coasting through intersections, and collisions resulting from brake failure. At least one owner drove approximately 50 miles with near-total brake loss.
Soft or spongy brake pedal—sinking to the floor and requiring pumping—appears intermittently from near-new mileage through 90,000+ miles. Some owners describe the problem as recurring several days in a row, then disappearing for extended periods.
ABS spontaneously activates during routine braking, causing violent steering-wheel shake and making the vehicle hard to control. Traction control lights illuminate without warning. One owner experienced right front caliper overheating to the point of flames and orange-glowing rotor while other wheels stayed cool—a sign of caliper lock-up.
Dealers have repeatedly replaced master cylinders (up to three times in one case) without permanently resolving failure. Wheel-speed sensor faults recur even after cleaning and part replacement. Multiple owners referenced Recall 07E105000 but were told their VINs were not covered, despite identical symptoms. One dealership reported a national backorder for master cylinders, suggesting widespread demand. Technicians have been unable to recreate failures during test drives, and one dealer was reportedly unauthorized to replace the brake pedal itself.
Failure modes owners describe
Right Front Caliper Overheating and Lock-Up
Right front brake caliper seizes, generating extreme heat (smoke, flames, orange-glowing rotor) while other wheels remain cool. Suspected inadequate brake fluid return from caliper causing excessive pressure.
When: Low-speed city and highway driving; at least 2 documented incidents in 2011-2012
Symptoms owners cite: Burning brake smell at low speeds; White smoke and flames from right front wheel; Caliper and rotor extremely hot; Orange-glowing rotor; Impaired braking after overheating
Repairs/costs cited: No repairs documented; owner attempted to cool brakes by coasting. Vehicle recovered function after ~1 hour cool-down.
Recalls/TSBs owners mention: Ford claimed VIN not affected by Recall 07E105000; owner unable to obtain defect clearance documentation from Ford or Continental.
Complete Brake Failure—No Response
Brake pedal pressed but vehicle fails to stop or responds with dangerously extended stopping distance. Incidents during emergency braking often result in accidents.
When: Various speeds (25–55 mph); multiple incidents per owner; some from early mileage (1,000–5,000 miles)
Symptoms owners cite: Brake pedal depressed with no stopping response; Vehicle coasts through stop signs/intersections; Abnormally extended stopping distance; Owner standing on brakes with no effect; Traction control light may illuminate simultaneously
Codes mentioned: ABS warning light (independent activation), Traction control light
Repairs/costs cited: Master cylinder replaced multiple times (up to 3 times in one case) without permanent resolution. Hydraulic control valve and brake master cylinder diagnosed in one case but not repaired. Some dealerships unable to diagnose or recreate failure during test drives.
Recalls/TSBs owners mention: Ford denied coverage under Recall 07E105000 for affected VINs. Authorized dealer unable to repair in at least one case (brake pedal replacement deemed unauthorized).
Soft/Spongy Brake Pedal—Excessive Travel
Brake pedal sinks abnormally low or goes soft, requiring multiple pumps to restore braking. Often intermittent; can occur on first brake application after startup or randomly during use.
When: From near-new (16 miles) through 90,000+ miles; intermittent, sometimes several days in a row, then absent for periods
Symptoms owners cite: Brake pedal sinks to floorboard without warning; Pedal feels soft or squishy; Excessive pedal travel before brakes engage; Requires pumping brake pedal to restore pressure; Pedal pulsates as if ABS is activated; Occurs at any speed or weather condition
Repairs/costs cited: Brake pads replaced (ineffective). Master cylinder ordered at one dealership; national backorder reported, suggesting industry-wide shortage. Bleeding brakes temporarily corrects issue in one case, but problem recurs.
Recalls/TSBs owners mention: Dealerships conflicted: some claim soft brakes are normal design; others acknowledge master cylinder failure. No widespread recall issued.
ABS Unwanted Activation—Loss of Braking Control
Anti-lock brake system activates without warning or valid condition, causing violent steering-wheel shake, uncontrolled vehicle behavior, and inability to stop normally. Traction control light often illuminates.
When: Various speeds (10–40 mph); repeated episodes; some occurring early in ownership
Symptoms owners cite: Traction control light illuminates without cause; Vehicle swerves back and forth; Steering wheel shakes violently; ABS activates when braking normally; Vehicle extremely hard to control and stop; Brake pedal extends to floorboard during ABS event
Codes mentioned: ABS light illumination, Traction control light
Repairs/costs cited: Yaw valve replaced (failure recurred 2 days later). Transmission replaced in one case. Repeated visits to dealer (3–4+ times) without permanent resolution. Dealers unable to locate failure codes or recreate issue during test drives.
Recalls/TSBs owners mention: Recall 07E105000 referenced by owners; Ford denies VIN eligibility. Engineer involvement requested by one dealership but issue unresolved.
ABS Wheel-Speed Sensor Faults
ABS warning light and traction control light activate due to wheel-speed sensor malfunction, typically rear driver side. Repeated cleaning and part replacement does not permanently resolve.
When: Early mileage (3,000–5,000 miles)
Symptoms owners cite: ABS warning light; Traction control light; Grease accumulation around wheel hub
Repairs/costs cited: Rear driver-side sensor cleaned; recurred 9 miles after repair. New parts ordered and installed; failure recurred again at 5,000 miles.
Recalls/TSBs owners mention: Dealership service performed under warranty; repeated attempts to correct without lasting success.
Brake Pedal Position Abnormality
Brake pedal positioned unusually far to the left (manual-transmission clutch position) or physically welded in place, making safe operation difficult or impossible.
When: At sale (used vehicle); not mileage-dependent
Symptoms owners cite: Brake pedal offset far left; Requires excessive foot movement to operate; Pedal may be physically welded; Right foot cannot comfortably reach; unsafe to use left foot
Repairs/costs cited: One vehicle (salvage rebuilt) had brake pedal welded; another had pedal misaligned. No repairs documented.
Recalls/TSBs owners mention: N/A—appears to be dealer/rebuild issue rather than manufacturer defect.
Parking Brake Inability—Vehicle Rollback
Vehicle rolls backward or downhill despite foot brake engaged and transmission in Park. Occurs on multiple separate occasions.
When: Parked on driveway
Symptoms owners cite: Vehicle rolls despite foot brake engaged; Vehicle rolls despite transmission in Park; Rollback occurs repeatedly
Repairs/costs cited: Dealership service unable to locate any issues.
Recalls/TSBs owners mention: No service action identified; issue unresolved.
Brake Fluid Leak—Master Cylinder to Booster
Master cylinder fails and leaks brake fluid into the brake booster, causing loss of braking power. Owner reported driving ~50 miles with near-total brake loss.
When: Mid-to-high mileage (~90,000 miles typical in narratives)
Symptoms owners cite: Brake pedal becomes weak; Warning light appears; Severe loss of braking power; Brake fluid visible in booster area
Repairs/costs cited: Master cylinder replacement; cost cited as ~$800. Owner drove extended distance (~50 miles) at reduced speed to reach service facility.
Recalls/TSBs owners mention: No recall issued. Owner referenced magazine article about Ford master-cylinder failures.
Intermittent Brake Ratcheting with Power Loss
Brake pedal ratchets downward, makes tapping sound, then loses braking power momentarily during normal braking.
When: At least 6 documented occasions
Symptoms owners cite: Pedal ratchets down; Tapping/grinding noise; Momentary loss of braking power; Occurs during normal braking
Repairs/costs cited: No repairs documented.
Recalls/TSBs owners mention: Owner referenced Recall 07E105000; no other manufacturer response recorded.
Air in Brake Lines—Recurring After Bleeding
Air enters brake hydraulic system repeatedly. Bleeding temporarily resolves symptoms, but problem recurs.
When: Intermittent; unspecified mileage
Symptoms owners cite: Soft brake pedal; Loss of braking force; Loss of anti-lock capability
Repairs/costs cited: Bleeding brakes temporarily corrects loss of braking force; problem recurs within unspecified time frame, suggesting slow leak or air entry point.
Recalls/TSBs owners mention: Owner referenced Recall 07E105000; suggests possible system design flaw allowing air ingestion.
Synthesized from 27 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.