NHTSA Complaint #737632 — 1994 FORD EXPLORER

VEHICLE PURCHASED 12/1996. BRAKES REPLACED FIRST TIME 03/02/1997 AT 66730 MILES. ON 08/31/1997 BRAKE PADS DISSINTEGRATED CAUSING BRAKE FAILURE. PADS, ROTORS, AND CALIPERS REPLACED ON 09/02/1997 AT APPROX. 70747 MILES. SAME PROBLEM OCCURS ON 02/02/1998 AT 74095 MILES, 06/11/1999 AT 84823 MILES, 07/13/1999 AT 85493 MILES, 03/16/2000 AT 90037 MILES, AND MOST RECENTLY ON 12/10/2000 AT 96878 MILES. ALL BRAKE PADS WERE RAYBESTOS SILVER INSTALLED BY NATIONAL TIRE AND BATTERY (FORMERLY TIRE AMERICA). MAJORITY OF MILAGE IS CITY. OTHER IS HIGHWAY. THERE ARE NO OFFROAD MILES. VEHICLE IS USED AS A PASSANGER VEHICLE NOT FOR HAULING OR TOWING. FAILURE OCCURS WHEN BRAKE PAD LINING CRACKS, CRUMBLES, AND DISSINTEGRATES LEAVING ONLY BRAKE BACKING AGAINST ROTOR FOR BRAKING. THIS USUALLY HYPER-EXTENDS THE CALLIPER AND SCORES THE ROTOR BEYOND REPAIR (TURNING DOWN) REQUIRING REPLACEMENT OF BRAKE PADS, ROTOR ASSEMBLY, AND CALLIPER ASSEMBLY. WHEN FAILURE OCCURS, THERE IS ABSOLUTELY NO BRAKING ACTION (PEDAL DROPS TO THE FLOOR) UNTIL BRAKE PEDAL IS PUMPED AFTER WHICH A GRINDING NOISE (BRAKE PAD BACKING INTO ROTOR) IS HEARD. FAILURE HAS USUALLY OCCURED AT LOWER SPEEDS WHEN APPROACHING A STOP. *AK