Front Brake Roughness Shudder while Braking – 2004-2006 Ford Expedition & Lincoln Navigator – Ford & Lincoln

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BRAKE SHUDDER

FORD:	2004-2006 Expedition
LINCOLN:	2004-2006 Navigator

2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006 may experience repeat front brake roughness and / or shudder while braking.

ACTION:

Determine if the vehicle has the old level rotors.

If old level rotors, replace the front rotors and front caliper assemblies.

If vehicle has new level rotors replace caliper assemblies and turn or replace the rotors as appropriate.

SERVICE PROCEDURE

Check the build date of the front rotors. The build date is stamped on the inside of the rotor, between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd), replace the front rotors and front caliper assemblies.

Figure 1

NOTE: REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS AUNIT WITHOUT DISASSEMBLY.

If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond machinable thickness, replace the front rotors.

NOTE: DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32″ (7 MM). THIS INCREASE IN TRAVEL IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING DISTANCE AND/OR BRAKE EFFECTIVENESS.