Complete Brake Failure
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Senior User
Joined: Dec 2009
Posts: 145
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Complete Brake Failure
Down hill toward intersection with light that turned red. I braked fairly hard and then all of a sudden, brake pedal goes to floor and I go through the light. I pump brake once or twice and still nothing. Luckily I made it through without hitting anyone and eventually stopped with emergency brake. Turns out the line to the rear brakes blew. It was probably weak and maybe the pressure from braking hard blew it. This was sudden. There was no warning whatsoever. Reservoir was empty and practically no brakes in the front. There was enough front brakes to keep the truck from idling forward, but that is it. I thought that I should have had full front brakes with a modern day master cylinder. Looks like Ford blew it with this one. Very dangerous design.
Is there an upgrade available? I never want this to happen again.
Is there an upgrade available? I never want this to happen again.
Elder User
Joined: Nov 2007
Posts: 854
Likes: 2
From: Middleburg FL
I have no idea if there is an update but I had the exact same failure, only I was pulling a #7000 trailer into Atlanta traffic on I75 at @70 mph when a semi cut into my lane and slammed on his brakes. I hit my brake pedal and then...it went to the floor, luckily I could stop on the trailer brakes and the emergency brake. The problem is that Ford used a single line that is @12-13 feet long to go from the front proportioning valve to the rear splitter.
Mine was replaced by Pep Boys with an upgraded HD line that they custom bent to move it farther away from the exhaust and driveshafts. I still don't like that it is one line but I needed it fixed so I could get home. Good luck with a solution. If you find one you won't be alone in doing it. 
Mine was replaced by Pep Boys with an upgraded HD line that they custom bent to move it farther away from the exhaust and driveshafts. I still don't like that it is one line but I needed it fixed so I could get home. Good luck with a solution. If you find one you won't be alone in doing it.
Senior User
Joined: Dec 2002
Posts: 218
Likes: 1
From: Rancho Cucamonga USA
Glad you didn't hit anything! That must have been quite an experience.
Stainless Steel Braided lines are my choice. There are several brands available I like Goodridge or Russell.
00-up Ford Excursion Brake Lines from Russell at Andy's Auto Sport
These are the calipers I want!
https://www.ford-trucks.com/forums/1...-calipers.html
Stainless Steel Braided lines are my choice. There are several brands available I like Goodridge or Russell.
00-up Ford Excursion Brake Lines from Russell at Andy's Auto Sport
These are the calipers I want!
https://www.ford-trucks.com/forums/1...-calipers.html
Fleet Mechanic
Joined: Sep 2002
Posts: 1,388
Likes: 2
From: Greensboro, NC
Sorry you had the problem and real glad you got it stopped safely! I'm not aware of an upgrade but there are definitely options on the type of line to use. I use nickel/copper line at my shop and eventually will use it on my Ex but so far the lines are in good shape with no exterior corrosion present all of the way back. The stainless line is a good option but a lot of shops do not have the flare tool for it. Stainless requires a single 37* flare while steel or alloy lines are a double 45* flare.
TreadLightly
Joined: Oct 2006
Posts: 1,608
Likes: 0
From: SE Missouri
Down hill toward intersection with light that turned red. I braked fairly hard and then all of a sudden, brake pedal goes to floor and I go through the light. I pump brake once or twice and still nothing. Luckily I made it through without hitting anyone and eventually stopped with emergency brake. Turns out the line to the rear brakes blew. It was probably weak and maybe the pressure from braking hard blew it. This was sudden. There was no warning whatsoever. Reservoir was empty and practically no brakes in the front. There was enough front brakes to keep the truck from idling forward, but that is it. I thought that I should have had full front brakes with a modern day master cylinder. Looks like Ford blew it with this one. Very dangerous design.
Is there an upgrade available? I never want this to happen again.
Is there an upgrade available? I never want this to happen again.
Where exactly was your break in the brake line? Do you have any pictures of the broken line?
TreadLightly
Joined: Oct 2006
Posts: 1,608
Likes: 0
From: SE Missouri
Glad you didn't hit anything! That must have been quite an experience.
Stainless Steel Braided lines are my choice. There are several brands available I like Goodridge or Russell.
00-up Ford Excursion Brake Lines from Russell at Andy's Auto Sport
Stainless Steel Braided lines are my choice. There are several brands available I like Goodridge or Russell.
00-up Ford Excursion Brake Lines from Russell at Andy's Auto Sport
If anyone else is considering them also, Autoanything has the same kit for $164 with free shipping.
Trending Topics
TreadLightly
Joined: Oct 2006
Posts: 1,608
Likes: 0
From: SE Missouri
Wow 
... I guess my family and I have been protected. Looks like it is more common then I thought. I will have to start adding this to the oil change regiment.
Googled "Brake Line Failure" on FTE
... I guess my family and I have been protected. Looks like it is more common then I thought. I will have to start adding this to the oil change regiment. Googled "Brake Line Failure" on FTE
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Hotshot
Joined: May 2005
Posts: 13,484
Likes: 42
From: Stevens Point, WI
I have had this happen many many times because of rusted lines and I agree the way the system is designed there should be some front brakes yet. But somehow ford designed the master to totally rely on the rear brakes to make the peddle and send fluid to the fronts. Your lucky your E-brake even worked! That is another ford failure.
you can't fix stupid!
Joined: Mar 2008
Posts: 1,906
Likes: 2
I'm gonna guess he blew out the flex hoses that go from the solid line to the caliper....just got done replacing all my brake lines with stainless braided lines and new fluid....better safe than sorry....
Thread Starter
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Senior User
Joined: Dec 2009
Posts: 145
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Thanks for all the info. My insurance company towed truck to nearest dealer and the dealer replaced the line made up with 2 pieces. I never got any photo's. The 2 piece line that failed was located along the drivers side frame rail between the engine and the rear axle. It rusted through in one spot near the rear axle and was severely rusted in another spot somewhere in the middle. This truck has never been on the beach, has very little rust underneath and only has 107,000 miles on it, so be careful regardless of mileage and condition. When this line fails, there are no brakes.
More Turbo
Joined: Sep 2003
Posts: 581
Likes: 7
From: IOWA
Wouldn't one think that this is a big enough problem for a recall? It seems a little too common for my liking. I crawled under and looked at mine, it's spotless so I am guessing it's been replaced by the previous owner.
Hotshot
Joined: May 2005
Posts: 13,484
Likes: 42
From: Stevens Point, WI
I've probably said 1000 times stainless brake and fuel lines should be standard on every vehicle!
Elder User
Joined: Nov 2007
Posts: 854
Likes: 2
From: Middleburg FL
My brake line split open along the frame rail above the transmission crossmember. I couldn't see the split, only the massive amount of fluid it blew all over everything. The tech brought it out after he removed it and the line only had a few spots of minor surface rust and those weren't by the split. They custom bent a replacement 1 piece line out of a 25' roll of brake line instead of splicing several smaller pieces.
I will say I had been awake for 23 hours at that point (thats why I let them do the repair) so my memory could be a little fuzzy...
I will say I had been awake for 23 hours at that point (thats why I let them do the repair) so my memory could be a little fuzzy...