NHTSA Complaint #10946801 — 2004 FORD MUSTANG GT

FRONT BRAKES DRAG OR FREEEZE UP CAUSING EXTREME HEAT OR ACTUALLY STOP VEHICLE. CAR HAS 18,000 MILES. FRONT CALIPERS HAVE BEEN REBUILT TWICE. FIRST FAILURE AT TEN YEARS,THEN FAILED AFTER APX 3 YEARS. THE PROBLEM IS THE PHENOLIC PISTONS SWELL AFTER TIME OR DUE TO LOSE OF LUBRICATION. THEY CHANGE DIMENSION AND STICK IN THE CALIPER. THIS IS THE 3 RD VEHICLE WITH THE SAME PROBEM. 81 FORD F150, 98 FORD F150 FRONT DISK BRAKES. BOTH AFTER THE VEHICLE HAD BEEN ON THE ROAD ABOUT 10 YEARS. WHEN PISTONS HAVE BEEN REPLACED WITH METAL PISTONS I HAVE HAD NO MORE ISSUES WITH THE FRONT BRAKES. THE MUSTANG HAS NO METAL PISTON AVAILABLE AND HAD TO BE REBUILT WITH AFTER MARKET PHENOLIC PISTONS. THEY FAILED AGAIN PROBABLY BECAUSE OF LACK OF LUBRICATION OF BOOT AND PISTON. SOMEHOW I FEEL THIS IS A CHRONIC FAILURE AND HAPPENS A LOT WITHOUT ANYBODY BEING AWARE THAT TIME AND OR HEAT AFFECT THE PHENOLIC PISTON AND CAUSE BRAKE FAILURE.THIS FAILURE IS STRICTLY VEHICLE RELATED AND NOT DUE TO ANY EXTERNAL CAUSES EXCEPT TIME, HEAT, OR LUBRICATION. I FEEL THE WEIGHT OF THE NON METALLIC PISTON DOESN'T COMPENSATE FOR THE COST OF THE BRAKE FAILURE THAT IT CAUSES. I'VE BEEN TOLD BY FORD THAT THE PHENOLIC PISTONS WERE SELECTED TO SAVE WEIGHT.