Hello all, I have a '03 SuperCrew with a very strange brake problem. The best way I can describe it is that at random times the brake pedal feels rusty and I have to push harder on the pedal then normal to engage them. I have about 25K on the truck; this started around 12K. It might happen 10 times within 100 miles then not act up again for another 1000 miles.

Once the "rust" brakes free they work like normal. The problem seems to be more severe at highway speeds, but I still notice it at lower speeds as well.

I have had the truck in 3 times for this problem. The dealer has felt the problem while test driving and has replaced more parts then I can remember. The local Ford rep has been called and is not aware of a known issue. Ford has agreed to come out and look at the truck but I was wondering if anyone has any ideas on what could be causing it?

While I am aware of the problem and have adjusted my driving habits accordingly, I don't like the fact that I own a fairly new truck that is having brake issues like this.

Any help would be appreciated.

Mark