Brake Dust Issue TSB
Customer dissatisfaction with brake dust level on vehicles produced before 12/18/2003.
The brake linings on 2003-2004 Expedition/Navigator vehicles are designed to interact with the brake rotors in such a way as to keep the rotors smooth, minimizing rotor runout and thickness variation. The brake dust that is generated as a result of this interaction does not indicate a performance concern with the vehicle's brake system, and is considered a normal condition by Ford Motor Company.
Ford Motor Company recognizes however that some customers may object to brake dust for appearance reasons. Effective 12/18/03, the brake linings on Expedition/Navigator have been revised. The revised linings will generate less dust. The revised linings are also being made available for service, as Service Kit 4L1Z-2001-BA. This kit contains BOTH front and rear linings. A coordinated front and rear lining change is required in order to avoid making the vehicle noncompliant with Federal Motor Vehicle Safety Standard 135. Do not mix the parts in the 4L1Z-2001-BA Kit with any other brake linings.
Per the Warranty and Policy Manual, parts and labor needed to maintain the vehicle due to normal wear and tear are the responsibility of the vehicle owner, and are not covered under the New Vehicle Limited Warranty. Because brake dust is due to normal wear and tear, replacing brake linings for a dust condition is not covered under bumper-to-bumper coverage. For 2003 model year Navigator customers the Lincoln Commitment covers normal brake wear (but not brake dust) for 3 years/36,000 miles, whichever occurs first. Some ESP plans may also cover worn brake linings. Consult OASIS to see if brake linings are covered as a provision of the customer's plan. Again, brake linings may be replaced for wear, but replacement of linings for a brake dust condition is not covered by either the New Vehicle Warranty, Lincoln Commitment, or ESP.
Replace brake linings, and ancillary parts if necessary, with revised brake linings.
Follow instructions included in Kit 4L1Z-2001-BA and Workshop Manual Sections 206-03 and 206-04.
NOTE: A COORDINATED FRONT AND REAR LINING CHANGE IS REQUIRED IN ORDER TO AVOID MAKING THE VEHICLE NONCOMPLIANT WITH FEDERAL MOTOR VEHICLE SAFETY STANDARD 135. DO NOT USE THE 4L1Z-2001-BA PART NUMBER WITH ANY OTHER REAR BRAKE LINING.
NOTE: IT IS NOT NECESSARY TO MACHINE THE ROTORS BEFORE INSTALLING THE NEW LININGS, UNLESS OTHERWISE DIRECTED BY THE WORKSHOP MANUAL.
NOTE: VEHICLES BUILT BEFORE JULY 15, 2003 MAY REQUIRE REPLACEMENT OF THE HOLD-DOWN CLIP, AND RETAINING PINS, THE FIRST TIME THE BRAKE LININGS ARE REPLACED. SERVICE KIT 4L1Z-2001-BA KIT CONTAINS DETAILS ON HOW TO DETERMINE IF THESE PARTS MUST BE CHANGED. YOU MAY WISH TO ORDER THESE PARTS ALONG WITH THE BRAKE LINING KITS, TO AVOID REPAIR DELAYS.
PART NUMBER PART NAME
4L1Z-2001-BA Brake Lining Kit
2L1Z-2B164-CA Clip - Hold Down
2L1Z-2C150-AC Kit - Retaining Pin