Originally Posted by lcarothers

I've done a search and don't seem to find our 2004 F150 brake problems here in this forum. Many other sites have thousands of 2004 owners with the same complaints and I'm hoping I've missed it or if one of you know the solution. We've lost count of the visits to the dealerships - somewhere btw 8-13, the dealerships for some reason do NOT enter each time you are there for the brake problem, as I have found this is the same pattern thru others online.
Our F150 started having a spongy pedal, excessive pedal travel (4" to hard pedal on the F150, my Explorer is 1")pedal to floor and warped rotors in the 1st 3000 miles. The rotors were replaced - only to warp again within 1000 miles - they were then turned. The brakes have been bleed several times. Repeated times we were told the brakes were normal - it's not normal to have to drive 2 footed. One foot pumping the brakes up, one for the accelerator. If by chance you negelect pumping the brake pedal and have to come to an emergency stop the pedal will go to the floor - we've had numerous near crashes due to these brakes. We went to another dealer after I phoned the 800 # for Ford - there is a TSB to replace the rotors and calipers with updated parts. These were replaced BUT we still have excessive pedal travel, STILL have to pump the brake pedal while driving. And we are still being told there is nothing wrong with our brakes. I do not drive my husbands truck unless it's an emergency - I'm afraid I will harm someone or of course. myself. (Not to mention I don't want to be the one driving when the failure occurs and I wreck my husbands truck!)
If anyone out there could address their pedal travel, I'd appreciate it. I would esp like to hear from someone who has had this problem and had it fixed properly.
My husband has a friend w/ a 2005 and it has some of the above mentioned brake problems, also.
This was to be my husbands dream - there were only 2 available in the US with all the bells and whistles, the interior, color, etc that he wanted at that time. I conned a dealership salesman to look it up, found one in Tennessee, on one on it's way to Georgia from the assembly plant in KC,MO,:we dealt with the GA dealer and they drove it to us in SC. We've had Fords all our lives, this is the first problem we have had that cannot be resolved.
Any and all comments are appreciated. We are desperate.