Should I buy a 2009 Ford Flex with documented brakes problems?

Depends on the price and the specific vehicle. Documented brakes issues should be priced into the purchase — if the seller is asking full retail, negotiate down by the expected repair cost. A pre-purchase inspection from an independent shop tells you whether THIS specific vehicle has already shown the symptoms or not.

2009 Ford Flex brakes problems

moderate 21 complaints filed with NHTSA · avg repair $450 · see brakes across all vehicles →

Failure mileage

Complaints

Recalls

Avg fix

$450

1crash

When does it fail?

Of the 21 brakes complaints filed for the 2009 Ford Flex, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 mi.

0-25k

1 (50%)

25-50k

1 (50%)

50-75k

0 (0%)

75-100k

0 (0%)

100-125k

0 (0%)

125-150k

0 (0%)

150k+

0 (0%)

Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.

What stands out

Of the 4 model years of Ford Flex we track for brakes problems, this one carries the most owner complaints on file — 21.

No new NHTSA brakes complaint has been filed on this vehicle in over 14 years — the issue may be aging out of the active population.

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.

Service Bulletin SSM 46132 Oct 2016

SOME 2008-2017 FORD/MERCURY/LINCOLN VEHICLES EQUIPPED WITH SYNC MAY GENERATE A VHR THAT IDENTIFIES A CONCERN WITH THE BRAKES AND SUSPENSION CATEGORY INDICATING SERVICE IS REQUIRED DUE TO A BRAKE SYSTEM WARNING LAMP BEING ILLUMINATED. IF THE PARK BRAKE WAS APPLIED WHEN THE VHR WAS GATHERING DATA FROM THE MAJOR VEHICLE SYSTEMS, THE BRAKES AND SUSPENSION MESSAGE WILL BE REPORTED AS THE VHR LOOKS FOR ANY WARNING LAMPS ILLUMINATED IN THE INSTRUMENT CLUSTER. RERUN THE VHR WITH THE ENGINE ON AND VEHICLE IN PARK, AND ENSURE THE PARK BRAKE IS DISENGAGED. IF THE SYNC VHR IS STILL REPORTING A CONCERN TO THE CUSTOMERS SYNC OWNERS ACCOUNT, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTION FOR DIAGNOSIS BY

full bulletin at NHTSA ↗

Service Bulletin SSM 46132 Oct 2016

full bulletin at NHTSA ↗

Service Bulletin AS-21769 Mar 2011

FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION.

full bulletin at NHTSA ↗

Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.

The failure pattern owners describe

The 2009 Ford Flex brake system shows a constellation of unresolved issues across 21 complaints, starting early and persisting across 160,000 miles in one documented case.

Pedal and pressure loss dominate early reports: brake pedal travels excessively toward or to the floorboard, sometimes failing to stop the vehicle. One owner replaced the entire brake system four times; dealerships repeatedly said they found nothing wrong or couldn't replicate the fault. In one case at altitude, brakes failed completely, causing property damage. Another owner reports spongy brakes and extended pedal travel requiring a brake booster replacement at 160,000 miles.

Grinding and wear afflict the front discs most: loud grinding noise comparable to a stone in the brake assembly. Some owners had pads and rotors replaced 2 to 7 times; one owner's vehicle had right rear caliper piston fully retracted with abnormal wear, and the part sat on indefinite back order at NAPA and Ford. A tire merchant reported NAPA had received "many reports" of right rear caliper defects.

Rear brake problems—excessive heat, smoking, and premature wear—recur even after warranty replacement at 15,300 miles. One owner reported rear rotors rusting and corroding rapidly; the dealer acknowledged "all Flex vehicles have this problem."

System-level failures include brakes seizing at low speed (20 mph), engine shutdown with simultaneous loss of power brakes and steering (repeated events, dealership unable to fix), and ESC/ABS simultaneously activating to lock out acceleration.

Dealer response: Diagnostic repeatability is rare; many owners report four or more visits without repair attempts. TSBs exist but parts remain unavailable or owners receive no assistance after warranty.

Same Ford Flex brakes reports on nearby years: 2010

Failure modes owners describe

Brake Pedal Goes to Floor / Soft Brakes

Brake pedal travels excessively toward or to the floorboard, indicating loss of hydraulic pressure or brake booster failure. Occurs both at rest and while driving.

When: 7,526 miles; 126,000 miles; 160,000 miles; various owners report intermittent onset

Symptoms owners cite: Pedal travels to floor when depressed; Spongy brake feel; Extended pedal travel before stopping; Pedal goes further down on cold start-up

Repairs/costs cited: Brake system replaced four times in one case; brake booster replacement recommended; dealer unable to replicate in most cases; owner paid out-of-pocket after warranty expiration

Recalls/TSBs owners mention: TSB issued; manufacturer recommendation to replace parts again; no recall; Ford stated no assistance once vehicle left manufacturing plant

Grinding Noise / Brake Pad and Rotor Wear

Loud grinding noise during braking, often compared to a stone jammed between pad and rotor. Front brakes most commonly affected. Recurring problem even after multiple pad and rotor replacements.

When: Various mileages; reported at 22,000 miles, 33,000 miles; some owners report intermittent recurrence

Symptoms owners cite: Loud grinding noise when braking; Brake shudder from disc brakes; Abnormal wear on pads and rotors; Momentary front wheel lockup in one case

Repairs/costs cited: Brake pads and rotors replaced 2–7 times per owner; rotors and brackets replaced; owner paid $139 for pads when dealer found service notice; part on back order at NAPA and Ford for rear caliper

Recalls/TSBs owners mention: TSB issued (multiple per one complaint); service order on file at dealer; Ford knowledge of problem unclear; no recall

Rear Brake Caliper Dragging / Overheating

Rear brake calipers stick or drag, causing excessive heat, smoke, and premature rotor wear. Parking brake not engaged, yet rear brakes self-apply and smoke.

When: 15,300 miles warranty replacement; recurring after that; <50,000 miles

Symptoms owners cite: Excessive smoke from rear brakes; Rear rotors and calipers overheat; Premature wear requiring replacement every 20,000–30,000 miles; Other drivers flag vehicle thinking brakes are on fire; Right rear brake piston fully retracted, abnormal pad wear

Repairs/costs cited: Rear rotors and calipers replaced at 15,300 miles under warranty; repeated after that; right rear caliper on indefinite back order at NAPA; owner responsible for cost after warranty

Recalls/TSBs owners mention: TSB 10-7-2 issued for dragging calipers; warranty replacement available early in vehicle life

Brake System Complete Failure / Brake Seizure

Brakes fail to stop vehicle effectively or seize completely, preventing acceleration or stopping. Occurs at low speeds and can cause property damage or near-crash situations.

When: 20,000 miles; 30,500 miles; high-altitude parking; after refueling in one case

Symptoms owners cite: Brakes fail to stop vehicle effectively; Brakes seize, preventing acceleration; Only rear brakes function after repair; Spongy brake feel at high altitude; AWD and ABS engage simultaneously, limiting acceleration to 5 mph

Repairs/costs cited: Brakes replaced; one owner reported property damage; continued issues post-repair; one owner still afraid to drive vehicle; repairs range from component replacement to full brake system overhaul

Recalls/TSBs owners mention: Manufacturer offered no assistance in multiple cases; dealers unable to diagnose in some cases; no recall issued

Engine Stalling / Loss of Brakes and Power Steering

Engine shuts off while driving, resulting in simultaneous loss of power steering and power-assisted brakes. Dealership unable to replicate or diagnose problem despite multiple visits and extended road testing.

When: Shortly after purchase (October 2009 model year); occurs at 20 mph and 55 mph; multiple owners affected

Symptoms owners cite: Engine shuts off without warning; Loss of power steering; Loss of power-assisted brakes; All warning lights illuminate; Check engine light activates; Vehicle coasts safely when incident occurs at low speeds

Codes mentioned: Check engine light

Repairs/costs cited: Dealership unable to diagnose or repair in multiple visits; no attempted fix due to inability to replicate; owner expressed frustration with four visits to dealership without resolution

Recalls/TSBs owners mention: No TSB listed per owner complaint; dealer contacted Ford for suggestions; Ford unable to provide guidance

ESC / ABS Malfunction Preventing Acceleration

Electronic Stability Control (ESC) and Anti-Lock Brake System (ABS) activate unintentionally, preventing vehicle acceleration and creating hazardous situations when entering traffic.

When: <500 miles on new vehicle; 30,500 miles

Symptoms owners cite: ESC indicator light flashing; ABS buzzing sound; Vehicle cannot accelerate beyond 5 mph; AWD and ABS engage simultaneously

Repairs/costs cited: Owner disabled ESC via dashboard switch to allow acceleration; vehicle not taken for diagnosis

Rear Brake Wear Imbalance

Rear brakes wear out prematurely and excessively faster than front brakes, indicating hanging-up calipers or brake system imbalance. Rear rotors rust and corrode rapidly.

When: 41,000 miles; <50,000 miles

Symptoms owners cite: Rear brakes completely worn while front brakes have >50% life remaining; Rear rotors rust and wear away quickly; Corrosive brake fluid deterioration

Repairs/costs cited: Rear brakes replaced at cost of $511.34; dealer stated all Flex vehicles have this problem

Recalls/TSBs owners mention: Dealer acknowledged problem as endemic to model

Brake Light Failure

Brake light does not illuminate when brakes are applied. Caused by detached auxiliary relay.

When: 39,000 miles

Symptoms owners cite: Brake light fails to illuminate when pedal depressed

Repairs/costs cited: Auxiliary relay was detached from vehicle

Recalls/TSBs owners mention: Manufacturer contacted but vehicle not repaired

Relay and PCM Power Failures with Brake Issues

Intermittent no-start conditions caused by relay failure and PCM (engine computer) power loss. Related to broader electrical issues affecting vehicle systems including brakes. TSB issued for rear brake caliper dragging.

When: Multiple incidents; 5+ towing events

Symptoms owners cite: Intermittent no-start behavior; Relay failure reducing power to PCM; Soaked PCM from environmental exposure; RFI (radio frequency interference) suspected; Multiple warning lights and check engine light

Codes mentioned: SERVICE ENGINE LIGHT, CHECK AWD

Repairs/costs cited: Relay replaced; PCM diagnostics performed; vehicle towed 4+ times; rear brakes repaired per TSB 10-7-2

Recalls/TSBs owners mention: TSB 10-7-2 for dragging brake calipers

Synthesized from 21 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.

What owners are reporting 2 most recent

brakes · 20,000 mi · filed 12/29/2011

Tl* the contact owns a 2009 Ford flex. The contact stated that while driving 15 MPH, the brakes seized. The vehicle was towed to an authorized dealer and the contact was informed that the brakes were defective. The brakes were replaced. Since the repairs were performed, the contact stated that only the rear brakes functioned and the thermostat would intermittently display very high temperature…

brakes · 25,000 mi · filed 12/28/2011

I purchased my flex new on oct 2009 and it has shut off while driving three times since I bought it. The first time it happened I was driving through my neighborhood (with my children in the car with me) at 20mph all the warning lights came on my engine shut off, loss of power steering, loss of brakes. Luckily I was able coast to the side of the street. I waited a few minutes and it wouldn't…

Had brakes trouble with your 2009 Ford Flex? 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 2009 Ford Flex?

It's a documented issue but not catastrophic. 21 complaints have been filed. Repairs average $450 and most owners catch it before it causes a breakdown.

At what mileage does the brakes typically fail?

Across the 18 complaints that reported odometer mileage, most brakes failures cluster between 20,000 and 39,000 miles, with the median around 25,577. A quarter of owners report trouble before 20,000; a quarter make it past 39,000. 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.

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/2009/Ford/Flex. 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.