Brake rotors warp excessively. Just purchased used vehicle, had to have the rotors turned and brake system serviced after 5,000 miles. Vehicle would vibrate excessively upon application of brake. Ford service representatives that inspected the brake system stated that the pads looked almost new. In doing research on the internet this exact scenario seems to be playing out with 2000 - 2004 Excursion models. Other owners claim to have the brake serviced and rotors turned every 15000 - 25000 miles. It seems that the rotors are not adequate to handle the weight of the vehicle with out needing excessive service on a frequent basis.

- Minden, NV, USA

My problem is the truck has warped 4 sets of front rotors in 80,000 miles. It has yet to even wear the rear rotors. Each time it has warped the rotors the pads were replaced. The first 2 sets of rotors were from Ford. I then purchased high performance slotted rotor with special pads. This made no difference to the warping problem. I have talked to other owners of Excursion and they are having the same problem. Ford says (dealer & factory rep) this is normal wear. My employment puts me on the road approximately 6 to 8 hours per day. I have owned a Ford Bronco full size, Ford F150 full size, Dodge Ram 2500, Nissan, plus several cars. This is the only time that I have ever had a warping problem. I feel the Excursion is putting too much pressure on the front brakes and/or not much on the rear. This seems to make the truck harder to stop in quick stops - thus may cause me to have an accident due to inability to stop in time.

- Annandale, VA, USA

While applying the brake pedal, the vehicle jerked and vibrated uncontrollably. However, the driver was able to maintain control of the vehicle and drove it to the dealer for inspection. The mechanic informed the driver that the rotors needed to be replaced.

- Burke, VA, USA

I started experiencing vibrating in my steering wheel during braking several months ago. The vibration continued to get worse. I had the brakes checked and I found out that all four rotors were warped on the vehicle. The vehicle only has 27000 miles on it and the brake pads are in excellent condition. Through research I found that many other people have had rotor problems at a very early stage on their Ford Excursion. Ford refuses to acknowledge a problem with the rotors or repair the problem at their cost.

- Baltimore, MD, USA

On 8-25-03, I took my 2002 Ford Excursion in to berryville Ford in berryville Arkansas because the vehicle would not stop in a reasonable distance. If you are going downhill and you have to brake suddenly and hard the brakes get hot and you lose them alltogether.this vehicle has only 27,774 miles. It has been in the shop three different times and thet R&R the brake booster they R&R the hydraulic control unit. The brake shoes have been replaced twice the rotors have been resurfaced and this vehicle will not stop. If you brake more than three tiomes the brakes will overheat and then you cannot stop at all. I feel this vehicle is unsafe to drive. It is currently sitting in the yard at the berryville dealership. The dealership cannot get authorization from Ford to change the rotors. This vehicle was purchased at berryville Ford and I was told by the service manager and the dealership manager off the record to take it somewhere else. They don"T know what is wrong. The engine is a V-10 at 20mph you may get it stopped but if you have a panic stop it will not stop.

- Blue Eye, MO, USA

Front rotors rusted in center area between rotor brake surface. At 30,000 miles my 2002 Ford Excursion started to shake violently when braking at speeds above 40 mph. Luck for us we were driving in lower speed conditions in residential traffic. I inspected the brake pads and rotors for problems and found large amounts of rust decay in the rotors causing the warping to the rotors. I have serviced the brake system and replaced the front rotors and pads with excellent results. I have kept these rotors if any one should like to further look into this situation. We live in the desert with very low rain or snow. Now salts are used in my home area. I have never seen such corrosion to and important safety system. If this is a problem that could cause harm to others I would like to get the word out. I regularly respond to accidents and vehicle equipment failures as firefighter/medic. Regardless of fault it is a professional duty to at least make this notification.

- Tonopah, NV, USA