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BrakesPart report

2004 Ford Excursion Brakes Problems

Complaints
5about this part
Share
5%of 95 total for the year
Median mileage
17,000miles
Trend
Not enough dataFewer than 15 complaints, too few for a reliable trend.

NHTSA recorded 5 complaints about the brakes of the 2004 Ford Excursion, 5% of the 95 complaints for this model year. Where a mileage was given, the median is 17,000 miles. 1 of these say a crash was involved, according to the filers.

Fewer than 15 complaints name this part, so treat the figures as a rough indication only.

Example complaints

Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.

“I had a 1998 expedition before buying my 2004 excurion, and I could not keep brakes on the expedition. When shopping for the Excursion I made it a point to ask if the brakes were more heavy duty due to my problems on the expecition. I was mislead to believe that the ton framework would translate into more heavy duty brake systems. I had my Excursion in for service at 20k and requested my brakes be examined when my tires are rotated. I picked the vehicle up to find the tires were never removed or rotated. …”

NHTSA complaint #10114740, filed 2005-03, 18,000 miles

“I was having a problem with the brakes on my 2004 Ford Excursion. The first time was around may of 2005 the truck had about 15000 miles on it. After driving it for short trip, every time I used the brakes, the whole front end and steering wheel would shake. The dealer machined the rotors and sent me on my way. Now it has 38000 miles and it's doing it again. It's so bad that you feel like every time you brake you might lose control. I don't think the front rotors on the truck are up to standards. The dealer says they can't help due to the mileage of the truck.”

NHTSA complaint #10167628, filed 2006-09, 15,888 miles

“Dt: vehicle was involved n an accident due to brake failure. The ABS went out. When opened the hood for investigation the master cyclinder separted from the brake booster cylinder. No lock on bolt and the nut sheared itself off. Called Ford and left message. Had to put new transmission at 16,000 miles as well. Had 2 mechanics look at this and suggested Ford should take notice.”

NHTSA complaint #10122503, filed 2005-07, 16,000 miles

“The contact owns a 2004 Ford Excursion. The contact stated that while driving approximately 5 MPH he depressed the brake pedal but the brakes failed to respond. The vehicle was towed to an independent mechanic who diagnosed that one of the brake lines was corroded and had a hole rusted through. As a result, the brake line needed to be replaced. The vehicle was repaired. The approximate failure mileage was 76,745.”

NHTSA complaint #10470749, filed 2012-08, 76,745 miles

Related service bulletins

Brakes: other model years

YearComplaintsShare of year
200535%
200455%
2003109%
20021713%
2001136%
20006312%
1999114%

Other parts of the 2004 Ford Excursion

Engine cooling
22 complaints
Electrical system
21 complaints
Fuel system
12 complaints
Vehicle speed control
9 complaints
Engine
7 complaints
Transmission and drivetrain
7 complaints
Tires
6 complaints
Visibility (wipers, defrost, mirrors)
5 complaints
Air bags
3 complaints
Exterior lighting
3 complaints
Latches, locks and linkages
3 complaints
Seats
3 complaints

← All problems reported for the 2004 Ford Excursion

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology