The contact stated while driving at 40 mph the vehicle rattled. The vehicle was taken to the dealership. The first time the front rotors had to be turned. Several thousand miles later the problem recurred. He took the vehicle to the dealership again. This time it was the rear wheel rotors. The rotors were turned. The third time he took the vehicle to the dealer have it serviced. This time the brake pads, and rotors were turned. The dealership told him it was the design of the brake system, the rotors were too small for the brake system. All repairs have been made at the contacted expense. Updated 1/19/2006 - the front rotors warped which caused pulsation while braking.

- Weed , CA, USA

Front disc brake rotors warp under normal driving conditions. This results in extremely violent shuddering and shaking of the steering wheel while braking at speeds over 40 mph. Rapid braking at freeway speeds are high risk for loss of control and collision. I bought this Excursion used with ~48,000 miles and have had the rotors resurfaced at ~ 60, 000 and 84,000 mi. At 93,000 miles I had to replace all 4 rotors because of repeated shuddering from rotor warpage and wear which cost me over $500 on top of the $400 I spent at 84,000 miles for a brake job. Six months and 14,000 miles later I am having the same problem and now the dealer tells me there is a Ford service bulletin recommending a new type of pad. They also told me they have four other Excursion owners that are having the same complaints and safety concerns requiring similar repairs. The front rotors are insufficiently engineered for the size and weight of this vehicle, and presents a safety risk for Excursion owners as well as surrounding motorists. Ford knows they have a problem but instead of doing the right thing and fixing it they are bleeding consumers for repairs of a faulty design while the government does nothing about it.

- Victoria, TX, USA

The rear windshield wiper does not operate due to the spring. Also, the brakes do not function properly due to the brake rotors. The vehicle will not stop accordingly.

- Mack, CO, USA

My Excursion has been to the dealership 8+ times since purchase in 12-2002. The brakes and suspension are the top recurring problems. I do not have enough room to conclude all problems. Brakes have been serviced 3 times at dealership, I have asked them to look at the brakes two times in the last two months because of difficulty stopping, they find no problems. I don't see how they can tell when my mileage in is the same as my mileage out. I don't think Ford wants to deal with this problem. They are waiting for someone to die, and in this huge vehicle it is going to have to be a major accident for that to occur. Why does someone have to die before this vehicle is recalled. I am afraid for my and my family's life. I bought this vehicle for safety and comfort, and I am afraid of it. I have tried trading it in but word must be out because no one wants to give me anything for it. What do myself and so many others have to do to get this problem taken care off.

- Monroe, MI, USA

Consumer stated brakes wore out prematurely. This part was replaced eight times. As a result when applying the brakes steering wheel vibrated violently.

- Homer Glen, IL, USA

Brakes squeaking after 500 mi. Took it to dealer, they stated it was normal due to new type pads with metal content. Began shuddering and pulling to side at 10K miles. Rotors turned 3 times between 10K and 35K miles. Rotors & pads replaced at 35K miles. Turned again at 42K miles. Problem persists. Dealer states it is due to driving habits.

- Roseburg, OR, USA

The front rotors were badly warped at 18,000 miles. The dealer replaced the rotors under warranty, but are warped again at 23,000 miles. Poor design and a safety hazard.

- Enka, NC, USA

The consumer took the vehicle to the dealership for an inspection. The mechanic informed the consumer that both front rotors cracked. The consumer had the rotors replaced. The consumer had continuous problems with the brakes and rotors.

- Piney Flats, TN, USA

When the brake pedal was depressed it failed to stop the vehicle immediately, and the entire front end vibrated. This resulted in extended stopping distance. On one occasion, the vehicle was involved in a rear end collision. Dealership replaced or resurfaced brake rotors every three to four months.

- Cambria Heights, NY, USA

While driving at any speed and with no warning brake rotors wore out, causing extended stopping distance. Dealer notified.

- Browning, MT, USA

When applied the brake at any speed vehicle vibrate. Dealer notified.

- Jefferson, NY, USA

Front rotors continually warping regardless of driving habits. Turned rotors twice in less than 10,000 miles and replaced them once. I was told by the dealer, it was due to the rotors being too small for such a heavy vehicle.

- Mtn Home Afb, ID, USA

I too have experienced warped rotors under normal operation. I have owned my 2000 Excursion since new and have already had my rotors resurfaced once. They lasted approximately three months before having to have them done again. My last visit cost me $500 and I expect nothing less from the dealer this time. The harmonic period seems to be most pronounced when braking at 50 mph with the severity decreasing at a standard bell curve above and below that speed. I am concerned of my safety when having to brake at highway speeds from loss of control or failure. Based on the complaints I have viewed, I would be in favor of a class-action suit with a redesign or buy-back remedy.

- Alexandria, VA, USA

I own a 2000 Ford Excursion and have had problems with the rotors warping since new. The dealers have said I was the only one with this problem but after seeing this web site I see that is not true. Also I had the bearings go out in the right front wheel almost leading to the tire falling off if my wife had not noticed it in time. The rotors have been replaced twice have been turned at least every 15,000 miles since new I have around 80,000 miles now. The dealer did the brakes three times until the warrnty ran out at 36,000 miles I have had them fixed myself since then. This truck is said to be heavy duty and I only tow a camper with it twice a year 60 mile round trip I feel like I should not be having this kind of problem. The severe shaking that is caused by this makes if difficult to drive for my wife since she is the primary driver of the car. I cannot wait till my lease runs out so I can get rid of this car. The dealers will not help me at all. Thank for and help you might can give william andrews

- Creedmoor, NC, USA

Consumer states while driving vehicle, applied brakes and without warning front end was vibrating violently dealer serviced vehicle after several thousand miles problem occurred again dealer then stated it's the wear and tear of the rotors.

- Knoxville, TN, USA

When applying brakes at any speed there is pulsation forward/backward motion. Also, vehicle is too heavy for the brakes. Dealer now recommends new front rotors, rotors are warped. The vehicle pulls to the right and the left. Consumer complains of stiff steering and the rear door doesn't open, nor does the passenger side rear door. It is hard to open from the inside.

- Anaconda, MT, USA

Front disc brake rotors warp under normal driving conditions. This results in extremely violent shuddering and shaking of the steering wheel while braking at speeds over 40 mph. Rapid braking at freeway speeds are high risk for loss of control and collision. Because of safety concerns I have had the rotors resurfaced at 16, 000 and 25,000 mi. At 31,000 miles I had to replace the rotors because of repeated shuddering from rotor warpage and wear. I have asked four other Excursion owners and they have the same complaints and safety concerns requiring similar repairs. Front rotors are insufficiently engineered for the size and weight of this vehicle, and presents a safety risk for Excursion owners as well as surrounding motorists. Even when serviced properly as outlined, shuddering returns quickly.

- Camino, CA, USA

Front disc brake rotors warp under normal driving conditions. This results in extremely violent shuddering and shaking of the steering wheel while braking at speeds over 40 mph. Rapid braking at freeway speeds are high risk for loss of control and collision. Because of safety concerns I have had the rotors resurfaced at 16, 000 and 25,000 mi. At 31,000 miles I had to replace the rotors because of repeated shuddering from rotor warpage and wear. I have asked four other Excursion owners and they have the same complaints and safety concerns requiring similar repairs. Front rotors are insufficiently engineered for the size and weight of this vehicle, and presents a safety risk for Excursion owners as well as surrounding motorists. Even when serviced properly as outlined, shuddering returns quickly.

- Camino, CA, USA

Concerned about rotors needing to be replaced at 38,30 miles and brakes have been replaced also I am concerned that this will be ongoing thing and concerned about my familys safety, hope to hear from you very soon.

- Amissville, VA, USA

When applying brakes at any speed there is vibration on right front of vehicle. Vehicle taken to dealer 4 times, rotors were grounded on two visits, but did not remedy problem. Also the right front tire blew out, causing damage to rim.

- Rancho St. Margarita, CA, USA