Had front rotors replaced yesterday, along with clutch packs. Have 13k on 04 FX4.
I'm very pleased with the dealer response to both problems,(brake shudder, slip clunk in rear end) which seems to be a common problem with the 04. I hope this solves the problems.

 

Question,

Do These New Rotors That Ford Has Will It Stop My Squeaky/growling Front Brakes When I Come To A Stop. I Asked My Dealer About The Noise And Was Told It Was B/c Of The New Kinds Of Pads And That It Is Normal And Nothing To Worry About. I Have A 04 Scab Fx4 W/ 16000 Miles.

 

I am with bamorris22, I had the rotors turned on my 00 f150 and I had to replace them 20k later. I used the premium NAPA rotors...last time I buy from them. When I put my wheels back on I sheared 2 lug studs...with a 4 way!

 

A lot of the problem with rotor wear is from the composition of the brake pads. The new pads are not made with asbestos like the old ones and have a high metallic content. I had the same problem on several of my new trucks, (I own a bussiness), and I had the pads replaced with ceramic pads from napa. They don't eat up the rotors as much, and double the life of the brakes. I'm sure this will not solve all the problems, but it should help. Hope this helps.

 

Does anyone know what the new TSB on the rotors states as warranty period. BA morris22 states that if you are still in warranty, then just go in and have it done, but I checked with my service dept. and they told me that the warranty on the new rotor TSB is 12 months or 12k miles. Has anyone had them covered beyond 12/12.

 

The TSB looks to be 04-26-11

FRONT END SHUDDER/VIBRATION WHEN BRAKING - VEHICLES BUILT BEFORE 11/18/2004

Publication Date: December 21, 2004

FORD: 2004-2005 F-150


This article supersedes TSB 04-15-01 to update the vehicle model years.

ISSUE:
Some 2004-2005 F-150 vehicles built before 11/18/2004 may exhibit a shudder/vibration from the front brakes when braking.

ACTION:
Replace the front rotors. Vehicles built prior to 8/20/2003, verify that the rack and pinion is at the latest design level. There will be a green dot on the rack and pinion bar code label. If there is no green dot, it will be necessary to replace the rack and pinion also. Refer to Workshop Manual Sections 206-03 and 211-02.


PART NUMBER PART NAME
5L3Z-1102-AA Rotor (4x2 Light Duty)
5L3Z-1102-BA Rotor (4x2 Heavy Duty)
5L3Z-1125-AA Rotor (4x4 Light Duty)
5L3Z-1125-BA Rotor (4x4 Heavy Duty)
4L3Z-3504-AB Steering Gear (Super Cab/Crew 4x2)
4L3Z-3504-BB Steering Gear (Super Cab/Crew 4x4)
4L3Z-3504-CB Steering Gear (Regular Cab 4x2)
4L3Z-3504-DB Steering Gear (Regular Cab 4x4)


WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION DESCRIPTION TIME
042611A 2004-2005 F-150 4x2: Replace Front Rotors, Inspect Rack And Pinion For Green Dot 0.7 Hr.
042611A 2004-2005 F-150 4x4: Replace Front Rotors, Inspect Rack And Pinion For Green Dot 0.6 Hr.
042611B 2004-2005 F-150 4x2: Replace Front Rotors, Inspect And Replace Rack And Pinion 1.7 Hrs.
042611B 2004-2005 F-150 4x4: Replace Front Rotors, Inspect And Replace Rack And Pinion 1.8 Hrs.

DEALER CODING
BASIC PART NO. CONDITION CODE
1102 42

--------------------------------------------------------------------------------

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.

Copyright © 2004 Ford Motor Company

 

Thanks for the post Lardman. The brake warranty is not defined in this bulletin. (LIMITED) being the key wording.
I checked with my dealer and they said that New Vehicle limited warranty coverage on these trucks for brake related problems is 12/12. Actually this is the second dealer that has told me that. Niether would give me the TSB number or a copy of the bulletin. I guess I will have to go directly to Ford Motor to get it straight from the horses mouth. Thanks for your post. I have ammo now.

 

Insynco, This is a link to FMC and it says everything is coverd 3/36, except tires:
http://www.ford.com/en/vehicles/vehicleShowroom/shoppingAdvice/warrantiesAndExtendedServicePlans/warranties.htm
I sent an email to a service manager I know, I'll let you know what he says.

 

"some maintenance and wear items have limited coverage, as follows:
Brake pad/lining replacements are not covered beyond 12 months or 18,000 miles, which ever occurs first." Source: Ford Cars and Trucks Warranty Guide.

i didn't see brake rotors included in the items they listed with limited coverage. they may make you pay for the pads, but if the rotors are bad, it should be covered under the 36/36 warranty.

 

Good link Lardy, that pretty well covers it.
I did discover that this factory warranty is not underwritten by FMC but a third party. So every time you need warranty work the dealer has to consult with this third party to get authorization. This is what the dealer told me, now whether it is true or not, dont know. Coming from the dealer I dont know what to believe any more.
I have searched for other posts on this subject and have determined that this rotor issue is not a widespread problem. Only a few posts on 04 warped rotors and very few who have gone to the dealer and had them changed. Unless I am missing something here. Thanks again.

 

insynco, Talked to my service manager he said: "THE WARRANTY COVERAGE STATES THAT MAINTENANCE WEAR ITEMS ARE WIPERS-BRAKE LININGS-CLUTCH LININGS AND BRAKE ROTORS ARE COVERED FOR 3 YRS OR 36K WHICH EVER IS FIRST PER THE WARRANTY AND POLICY MANUAL PG 3-7-SECTION 3 -HOPE THIS HELPS". Let us know what happens!

 

Just got back from the dealer. Went back to the same dealer and the service writer still insisted that the brake rotors were 12/12 warranty. I whipped out my TSB and layed it on him. He then had to consult with the service tech. After test driving my truck he came back and said no problem, I get the rotors under warranty, but I would have to pay for the metalic pads.
They had to order the rotors, and I will go back in to have them installed. I already have the updated rack so I wont need that.
Looks to be a happy ending to the rotor saga for me, considering I have 35,365 miles on my truck and if it had'nt been for helpful posts on this thread I would be dealing with this out of my own pocket. Thanks again

 

I had this problem too. I took it to the dealership to get it looked at, and they initially offered to resurface them for me. I raised a little *Heck*, and told the service manager he was full of crap. If the rotors were not good quality to begin with, what's resurfacing going to accomplish? Besides maybe prolonging your problem, and making you waste more of your time going back to the dealership again and again to have them resurfaced again. So, they replaced my rotors, and I have been trouble free. Don't let them waste your time with resurfacing, make them replace the rotors. Their service bulliten tells them that they should be replaced, when they offer to resurface them, they're just trying to save Ford some money.

 

Guys,

Why is it that some truck have the rotor warping problem and not others?

I have an 04 SCAB FX4 and have NO braking issues at all. I'd love to get the rotors upgraded to the new part number but I doubt Ford will do that unless my brakes are symptomatic.

?

CMOS

 

I bought my 04 with 8000 miles on it. I noticed the rear rotors had deep groves in them. I brought it back to the dealer and they said it was normal. Normal to who I asked. I simply said if you are no going to replace them I will just wait for the customer satisfaction survey and fill in my concerns. The next day I had new rotors on my truck. One is to assume that the dealer does not like doing warranty work. Sometimes who have to be a little demanding!!!