2022 Ford Everest brakes

Ford SA state that if one of your 4 brake disc's warped after 12 months or 30000km it is normal wear and tear. please see below communication. To Ford.. During April 2022 I bought a new Ford Everest 2.0l bi-Turbo 4WD Limited from Kouga Ford in Humansdorp, Eastern Cape Province. On the 29th of December 2023 I was driving the vehicle nearby Wilderness when the brakes suddenly released while applying pressure on the brake paddle. Luckily the brakes re-engaged after immediate reapp**** the breaks. Obviously this was extremely dangerous and endangered the lives of not only myself and my family (who was with me in the vehicle) but also other road users. At this stage the vehicle had only done approximately 28 000 kilometers. At that stage, since I was on my way back to my home in Jeffrey's Bay, I had no choice but to continue driving cautiously. During the rest of the journey the brakes, whenever I app**** them, shuddered. This also continued thereafter. Because the vehicle was due for its 30 000km service in a couple of weeks (at that stage) at Kouga Ford, I decided to wait until then to report the incident and continuing problem to their technicians and staff. After I informed them as aforesaid at the service, a service technician took the vehicle for a test drive where after he also confirmed that the brakes shudder when app****. The service technician reported it to the service manager at Kouga Ford. Thereafter Kouga Ford informed me that the brake discs were warped and needed to be "machined" but also that this, according to Ford Warranty policy, was not covered under the warranty as it falls under wear and tear. Hence, I was informed, I needed to pay for this. I did not agree with this and refused to pay for the work. I then I collected my vehicle after the service was completed but without any repair work on my brakes having been done because of the Ford service and warranty policy not covering it. During this period, I waited for the complaint that I had lodged with Kouga Ford regarding the brakes to be resolved by Ford SA and there were back and forth communication regarding the whether the repairs would be covered by the warranty, between Kouga Ford and Ford SA. As I did not have another vehicle to use during this entire period, I had no choice but to use the vehicle in question. During the period after the service on the 5th of March 2024, and while Kouga Ford was communicating with Ford SA to try and resolve this problem, I had another incident while driving on the N2. During this incident I app**** the brakes and the vehicle, as result thereof, violently swerved to the left to such an extent that I almost overturned the vehicle. I believe that the cause of this was that that right side brakes did not engage and only the left side brakes engaged when I app**** the brakes. The faulty brakes therefor, once again, almost cost me my life and caused a massive accident wherein other vehicles could have been involved had I not been able to avoid a collusion. I reported this to Kouga Ford as well. Thereafter Ford SA requested Kouga Ford to measure the brakes of the vehicle. I took the vehicle to Kouga Ford and they did so and provided the readings to Ford SA but I never received any feedback on the measurement of my brake discs compared to new specifications, if any, nor was I informed what the wear was. Kouga Ford then asked me to bring the vehicle back again to see if they can’t resolve the problem. They then also provided me with a vehicle to use while they investigate further. Thereafter Kouga Ford informed me that the front brake disc’s needed to be replaced but that Ford SA still refused to cover this under the warranty and that I would need to pay for this. Kouga Ford, wanting to assist me, then asked if they could send it to be machined and that they would bear this cost, considering the safety risk I agreed to it as a short-term solution to enable me to use my still very new vehicle. The machining of the brakes was competed by Delco in Humansdorp on Wednesday the 24th of April 2024 and the brake system is working for now. I also requested a report from on the repairs from Delco in Humansdorp. After receiving photos and videos it was abundantly clear that only one front disc was warped and that the other disc was still in a very good condition. This, according to my understanding, was also most probably the explanation for why the vehicle swerved to the left on applying the brakes during the incident referred to herein above. To conclude, I do not except Ford SA's claim that the warped disc brake is normal wear and tear for a vehicle that had only done 28 000 kilometers. I never experienced, nor did any of the experts that I contacted for advice, warped brake discs at 30 000km on any vehicle driving under normal conditions, not even considering the fact that the Ford Everest Limited is supposed to be a premium luxury 4X4 SUV. I called numerous Ford and other manufacturer dealerships across South Africa and not one agreed that this warped disc brake is caused by wear and tear. I also drive a 2006 Nissan Pathfinder 4l 4X4, now with 242 000km on the odometer, and I have never had to machine or replace any of the brake discs. I was informed by experts in this field, and I also know, that there are many causes for brake’s to shudder due to variation in disc thickness as a result of uneven wear to the discs which can be caused by the brake calipers not operating correctly, the rotors not having been installed properly or the proper bedding-in process not having been app**** if new brake pads have been installed and manufacturing defects to the rotor discs. Consequently, the only reasonable assumption to make is that Ford SA is conceding that the brake discs on its vehicles is simply sub-standard and that if you buy a Ford you can expect the brake discs to fail after approximately 28 000 kilometers and that it will not be covered under the warranty because such a failure would be normal wear and tear for Ford brake discs at such an early stage. If this is accurate I invite Ford SA to confirm that it would be considered normal practice to replace the brake discs on their vehicles on 30 000km and or every 30 000km. To summarize, I will not accept that a vehicle that had only done 28 000 kilometers or even 30 000 kilometers, could have suffered enough wear on brake discs to such an extent that one would be required to replace the discs. On Ford SA's version this would in any event mean that all four brake discs would have had similar wear and not only on one brake disc, to such an extent as to warp due to "normal" wear and tear. I therefore expect, and hereby again request, Ford SA to replace my all four brake discs on the vehicle. I also request Ford SA's descision in this regard in writing as I reserve my right take further steps, legal or otherwise, if Ford SA persists with their refusal to replace the brake discs.

Reply from Ford

Good Afternoon Mr. Noeth, I hope this message finds you well. We have escalated your dispute regarding the brakes to our Technical team for a thorough review. After carefully examining the provided pictures, videos, job card report, and feedback from the dealer, the team has concluded that the brake failure was due to wear and tear, not a manufacturer's error. The dealer has confirmed that the brakes were in perfect condition when the vehicle was sold to you. As wear and tear items are not covered under warranty, we regret to inform you that your claim has been declined. However, as a goodwill gesture, the dealer's sales team has covered the cost of having the brakes skimmed.

Additionally, the Field Service Engineer and Zone Manager have reviewed the matter and concur that no further assistance can be provided.

Based on this information, we consider this matter resolved and will close the case. Should you require any additional information or have further inquiries, please do not hesitate to contact us at ***. Thank you for your understanding and cooperation