My 2007 has had the same issue since 10K miles. Its been to the dealer 4x -- about every 15K mis. with the same issue. At 10K mi. the dealer asked if I had driven through some cold water! I told him that the ads show the truck driving over mountains, snow and through brick walls. They "fixed it" and I was told they replaced the parts. Again at 25K, again at 40K and again a 54K when they told me it was not covered by warranty and the rotors could not be turned any more. I had specifically reqeusted each time before that they put on new rotors and each time they said "yes we did". This was now the first time they admitted that they simply turned them each time before. I told them that was exactly why I requested new ones, because turning bad rotors, is like plaining a warped board -- it is still warped, just thinner in the high spots. Also, kicking the can down the road would lead to a no warranty issue. Of course I originally bought the extended Ford warranty to 6yrs 75K. After two weeks of fighting with Corporate Ford, they agreeded to replace the rotors at a warranteed cost to me of $100 (as opposed to the $900 they quoted for the two fronts!). Angry, I accepted. . . . at approximately 60K mi, I began feeling the old familiar wheel shake upon braking.
I do not abuse my truck, take it off road or subject it to any adverse conditions. I drive to work on nice streets and on the highway from time to time. Routine -- perhaps pampered use, for a truck of this caliber.
This is a known and common problem. Search the web, there are hundred of posts like yours. Cheap rotors. These are great trucks overall, but there are certain corners Ford just cannot seem to help itself on cost cutting (ie. the 1960's paper speaker cones, the napkin-sized floormats, annoying Radio Shack close-out fuel alarms, dim headlights, etc.). The rotors are simply of poor quality or insufficient for the load. What other 2011 vehicle requires you to use the parking brake in traffic? Really? I have a 1996 Landcruiser with 200K mi. with original front rotors -- no shake (and it has been off road and through cold water!).
Do yourself a favor and get a set of EBC's or Roto Pros and get on with enjoying your truck. Do not waste time or money on the stock Ford rotors. If they replace yours under warranty, then great. But know what is coming and do not waste time arguing with Ford. The aftermarkets I mentioned will improve your braking performance anyway so they are a clear upgrade and good investment.
Last edited by Centexrider; 10-10-2012 at 08:04 PM.