2009 Ford Flex Brakes Problems

The contact owns a 2009 Ford Flex. The contact stated that after refueling the vehicle, the odor of fuel was present coming from the vehicle. After parking inside the garage, there was fuel leaking from the seam of the fuel tank on the passenger’s side. The cause of the failure was not yet determined. Also, while attempting to stop the vehicle, the brake pedal would extend to the floor and the vehicle would not immediately stop. The contact determined that the brake booster was faulty and needed to be replaced. The vehicle was not yet repaired. The manufacturer and an unknown dealer were notified of the failure. The failure mileage was approximately 160,000.

TOOK CAR TO TIRE MERCHANT TO REPLACE TIRES. THEY REPORTED TO ME A PROBLEM WITH RIGHT REAR BRAKE. PISTON IS FULLY RETRACTED OUT, AND BRAKE PADS HAVE ABNORMAL WEAR RELATIVE TO OTHERS ON CAR. SUGGESTED THAT I CONTACT DEALER FOR REPLACEMENT OF BRAKE CALIPER. ALSO REPORTED THAT THEY CONTACTED NAPA, AND WERE TOLD THAT NAPA HAD RECEIVED MANY REPORTS OF RIGHT REAR BRAKE CALIPER ISSUES ON 2009 FLEX, AND IN FACT, NAPA HAS PART ON INDEFINITE BACK ORDER. PART ALSO ON BACK ORDER AT FORD (ONLY FOR RIGHT REAR BRAKE, APPARENTLY DEFECT ISOLATED TO THIS BRAKE), ALTHOUGH PLACED ORDER FOR PART TODAY. TOLD THAT THERE WAS NO RECALL ALTHOUGH THERE WAS A SERVICE BULLETIN SO I WOULD BE RESPONSIBLE FOR ALL COSTS OF REPLACING DEFECTIVE PART SINCE MY CAR RECENTLY WENT OUT OF WARRANTY. *JB

MY 2009 FORD FLEX LIMITED FWD HAS LESS THAN 50K MILES AND THE REAR ROTORS HAS BEEN REPLACED TWICE. THEY RUSTED AWAY, CORROSIVE BRAKE FLUID CAUSES RUST. MY DEALER KEEPS SAYING THAT ALL FLEX VEHICLES HAVE THIS PROBLEM. *TR

2009 FORD FLEX-COMPLETE BRAKE FAILURE AFTER SITTING FOR A PERIOD OF TIME AT HIGH-ALTITUDE. BRAKES HAD FELT SPONGY OTHER TIMES BUT WE THOUGHT IT WAS DUE TO ICY PARKING LOT-AS AFTER DRIVING A BIT BRAKES FELT OK. THIS TIME BRAKES FAILED COMPLETELY RESULTING IN PROPERTY DAMAGE. CAR TOWED TO LOCAL FORD DEALERSHIP -- THEY TOLD US THE BRAKES WERE FINE AND THERE HAVE BEEN NO ISSUES WITH BRAKES ON THE FORD FLEX--WHICH AFTER RESEARCHING WE KNOW TO BE FALSE. THE BRAKES STILL DO NOT FEEL RIGHT UPON START-UP-BRAKE PEDAL GOES FURTHER DOWN BEFORE STOPPING; WE NOW WAIT A PERIOD OF TIME BEFORE DRIVING--WE ARE AFRAID TO DRIVE CAR BUT DON'T HAVE THE MONEY TO PURCHASE A DIFFERENT AUTOMOBILE-AND DON'T WANT TO PASS A DANGEROUS CAR TO ANOTHER FAMILY. *JS

TL* THE CONTACT OWNS A 2009 FORD FLEX. THE CONTACT STATED THAT WHEN THE BRAKE PEDAL WAS DEPRESSED, THE PEDAL TRAVELED TO THE FLOORBOARD NUMEROUS TIMES. THE DEALER (GANLEY FORD WEST, 16100 LORAIN AVE, CLEVELAND, OH 44111, (216) 941-9800) REPLACED THE BRAKE SYSTEM FOUR TIMES. THE DEALER STATED THAT THERE WERE INTERNAL FAILURES WITH THE FRONT AND REAR BRAKE SYSTEM (ANTI-ROTATION PIN, ADJUSTER SPRING, SPRING SEAT, PISTON SEALS, SLIDER FRAME, ANTI-RATTLE CLIPS, SLIDER PINS, AND CALIPER FRAME). THE FAILURE CONTINUED. THE BRAKES HAD BEEN REPLACED EVERY 20,000 MILES. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THERE WAS NO RECALL FOR THE BRAKES. THE MANUFACTURER MADE A RECOMMENDATION TO HAVE THE DEALER REPLACE THE PARTS AGAIN. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 20,000.

AT MY LAST SERVICE AT MY DEALERSHIP, I WAS INFORMED THAT MY REAR BRAKES WERE WORN OUT AND NEEDED REPLACING WHILE MY FRONT BRAKES WERE STILL IN GOOD CONDITION. *TR

INTERMITTENT NO START OF VEHICLE. TOWED TO DEALER AFTER 5 PREVIOUS INCIDENTS. DELIVERED TO DEALERSHIP IN SAME NO START BEHAVIOR. UPON INITIAL ATTEMPT A RELAY WAS REPLACED AS THE PCM (MAIN ENGINE COMPUTER) WAS NOT RECEIVING POWER. SERVICE ADVISOR CALLS TO INDICATE VEHICLE IS READY AND STARTS UP AFTER REPAIR. AT THE DEALERSHIP, PICKING UP THE VEHICLE, CAR STARTS UP, HOWEVER, DASH LIGHTS LIGHT UP, WARNING "CHECK AWD, CHECK THIS, CHECK THAT..." SERVICE ENGINE LIGHT ON AS WELL (THE WRENCH). SHUT THE CAR DOWN, TRY TO RESTART, WILL NOT RESTART. TECH IS WITH ME AND OBSERVES BEHAVIOR AND TRIES AS WELL. NO START AGAIN. TECH ATTEMPTS TO DOWNLOAD ERROR CODES. MENTIONS RFI INTERFERENCE. WILL BE DOING ANOTHER DIAGNOSTIC. PREVIOUSLY, CAR WAS TOWED TO DEALERSHIP FOR STALLING AT FREEWAY SPEEDS (65+). ENDED UP BEING A SOAKED PCM (MAIN ENGINE COMPUTER). THIS TOOK TWO TRIPS (TOWED BOTH TIMES). THIS IS NOW FOUR TIMES TO REPAIR THE SAME NON-RUNNING / NO START DEFECT. THE REAR BRAKES WERE ALSO REPAIRED DUE TO DRAGGING CALIPERS AS PER TSB 10-7-2. *TR

TL* THE CONTACT OWNS A 2009 FORD FLEX LIMITED. THE CONTACT STATED THAT THE BRAKE LIGHT FAILED TO ILLUMINATE WHEN THE BRAKES WERE APPLIED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE DEALER CONFIRMED THAT THE AUXILIARY RELAY WAS DETACHED FROM THE VEHICLE. THE MANUFACTURER WAS CONTACTED BUT THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 39,000 AND THE CURRENT MILEAGE WAS 46,000.

OUR FORD FLEX CAME TO A STOP, (ENGINE DID NOT SHUT OFF) FROM APPROX. 10 MPH, WITHOUT THE DRIVER, MY WIFE, APPLYING THE BRAKES, IN A MALL PARKING LOT. SHE SHUT IT OFF AND STARTED IT AGAIN. IT DROVE FINE. SINCE WE HAVE HAD BRAKE ISSUES WITH THE FLEX BEFORE, WE IMMEDIATLY TOOK THE FLEX TO THE DEALER. THE DEALER SAID THEY COULD FIND NOTHING WRONG, EVEN DRIVING IT "20 MILES" AROUND TOWN TO REPLICATE ANY PROBLEM. THEY ALSO SAID THEY CONTACTED FORD FOR ANY SUGGESTIONS. WE PICKED THE CAR UP TWO DAYS LATER AND MY WIFE & DAUGHTER DROVE THE CAR 350 MILES TO VISIT RELATIVES. WHILE ON THIS TRIP, THE CAR STALLED, ENGINE QUIT, IN TRAFFIC AT ABOUT 15 MPH. THIS HAPPENED RIGHT AFTER FILLING THE FLEX WITH FUEL. THE CAR STARTED AGAIN AND WAS TAKEN TO THE LOCAL FORD DEALER, WHERE THEY FOUND NOTHING WRONG. WE HAVE HAD MANY BRAKE ISSUES AS WELL WITH THIS VEHICLE. THE REAR BRAKES SMOKE FROM SELF APPLICATION (THE PARKING BRAKE WAS NOT ON), ENOUGH SMOKE THAT OTHER DRIVERS HAVE WAVED US DOWN ON THE ROAD THINKING THE FLEX'S BRAKES WERE ON FIRE. WE HAVE HAD THE REAR ROTORS AND CALIPERS REPLACED AT 15,300 MILES (UNDER WARRANTY) DO TO EXTREMELY QUICK WEAR. THE REAR BRAKES HAVE SMOKED AGAIN SINCE THIS REPLACEMENT. I'M BEGINNING TO THINK THESE PROBLEMS ARE RELATED IN THE ABS/TRACTION CONTROL/STABLITY CONTROL SYSTEM. OF COURSE, THE DEALER, AND APPARENTLY FORD, SAY THERE IS NOTHING WRONG. THE TRANSMISSION CLUNKS ("NOTHING WRONG") AND IS RELUCTANT TO DOWNSHIFT (SAFETY FACTOR WHEN IN TRAFFIC), THE FRONT BRAKES ARE MAKING THAT GRINDING NOISE OTHER OWNERS HAVE COMPLAINED ABOUT, AND TRIM PIECES FALL OFF THE CAR. THIS IS MY WIFE'S VEHICLE TO TRANSPORT KIDS IN AND WE ARE EXTREMELY FRUSTRATED WITH OUR FLEX AND FEEL THIS "FAMILY CAR" IS UNSAFE. WE ARE CONSIDERING CALIFORNIA'S "LEMON LAW" IF FORD AND THEIR DEALERS DON'T ACKNOWLEDE THAT THE FORD FLEX HAS SOME SERIOUS PROBLEMS.

TL* THE CONTACT OWNS A 2009 FORD FLEX. WHILE DRIVING APPROXIMATELY 5 MPH, THE VEHICLE WOULD NO LONGER ACCELERATE. THE CONTACT ATTEMPTED TO ACCELERATE BEYOND 5 MPH BUT THE VEHICLE WOULD NOT RESPOND. THE VEHICLE WAS PULLED OVER AND SHUT OFF. UPON RESTARTING, THE CONTACT WAS ABLE TO CONTINUE DRIVING NORMALLY. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS TOLD THAT THE ALL WHEEL DRIVE AND ANTI LOCK BRAKING SYSTEM ENGAGED SIMULTANEOUSLY, NOT ALLOWING THE VEHICLE TO ACCELERATE BEYOND 5 MPH. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 30,500.

TL* THE CONTACT OWNS A 2009 FORD FLEX. THE CONTACT STATED THAT WHILE DRIVING 15 MPH, THE BRAKES SEIZED. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE BRAKES WERE DEFECTIVE. THE BRAKES WERE REPLACED. SINCE THE REPAIRS WERE PERFORMED, THE CONTACT STATED THAT ONLY THE REAR BRAKES FUNCTIONED AND THE THERMOSTAT WOULD INTERMITTENTLY DISPLAY VERY HIGH TEMPERATURE READINGS. THE VEHICLE WAS NOT TAKEN BACK TO HAVE THE ADDITIONAL FAILURES DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 20,000.

HAD GRINDING NOISE IN FRONT BRAKES, JUST LIKE A STONE HAD GOT JAMMED BETWEEN THE BRAKE PAD AND ROTOR. RIGHT FRONT WHEEL LOCKED UP MOMENTARILY ONE TIME. HAD IT BACK TO DEALER TWICE BUT THEY COULD NOT SEE A PROBLEM. FINALLY AFTER THE FRONT WHEEL LOCKED UP THEY REPLACED THE FRONT BRAKE ROTORS AND BRACKETS BUT I HAD TO PAY 139.00 FOR THE NEW PADS HAD APPROX. 33000K ON VEHICLE, THEY DID FIND A SERVICE NOTICE THIS LAST TIME. *LN

I HAVE A 2009 FORD FLEX WITH 41,000 MILES. THE REAR BRAKES COMPLETELY WORE OUT WITH OVER 50% LIFE LEFT ON THE FRONT. THIS IS IMPOSSIBLE UNLESS THERE WAS A PROBLEM WITH THE BRAKES HANGING UP WHEN SOLD. THE SERVICE CHARGE WAS $511.34. THE BRAKES WERE REPAIRED. FORTUNATELY THE FAILURE OF THE REAR BRAKES DID NOT RESULT IN ANY CONSEQUENTIAL DAMAGE. *TR

I PURCHASED MY FLEX NEW ON OCT 2009 AND IT HAS SHUT OFF WHILE DRIVING THREE TIMES SINCE I BOUGHT IT. THE FIRST TIME IT HAPPENED I WAS DRIVING THROUGH MY NEIGHBORHOOD (WITH MY CHILDREN IN THE CAR WITH ME) AT 20MPH ALL THE WARNING LIGHTS CAME ON MY ENGINE SHUT OFF, LOSS OF POWER STEERING, LOSS OF BRAKES. LUCKILY I WAS ABLE COAST TO THE SIDE OF THE STREET. I WAITED A FEW MINUTES AND IT WOULDN'T START. I TRIED TO START IT AGAIN AND IT STARTED UP. THE SECOND TIME I WAS DRIVING ON THE HIGHWAY(WITH MY CHILDREN IN THE CAR WITH ME) AT 55MPH ENGINE SHUT OFF, LOSS OF POWER STEERING, LOSS OF BRAKES AND CHECK ENGINE LIGHT CAME ON, I COASTED TO THE SHOULDER, WAITED A FEW MINUTES AND IT STARTED RIGHT UP. I TOOK IT TO THE DEALERSHIP; THEY TOLD ME THEY COULDN'T FIND ANY ISSUES THAT WOULD CAUSE THE VEHICLE TO TURN OFF WHILE DRIVING SO THEY DIDN'T ATTEMPT TO FIX IT. THE THIRD TIME WAS LAST WEEK WHILE DRIVING THROUGH MY NEIGHBORHOOD(WITH MY CHILDREN IN THE CAR WITH ME) AT 20 MPH, ENGINE SHUT OFF, LOSS OF POWER STEERING, LOSS OF BRAKES AND CHECK ENGINE LIGHT CAME ON. I TOOK IT TO THE DEALERSHIP AGAIN AND AGAIN THEY TOLD ME THAT THEY COULDN'T DUPLICATE THE ISSUE SO THEY DIDN'T ATTEMPT TO FIX IT. MY CHILDREN WERE IN THE CAR WITH ME ALL THREE TIMES. I'VE TAKEN TO THE DEALERSHIP 3 TIMES FOR THIS ISSUE AND THEY CANT DUPLICATE THE ISSUE SO THEY CAN'T FIND THE PROBLEM SO THEY DIDN'T EVEN ATTEMPT TO FIX IT. I JUST DROPPED IT OFF THIS WEEK FOR THE FOURTH TIME. ITS VERY FRUSTRATING TO HAVE THIS ISSUE ESPECIALLY SINCE IM SCARED TO DRIVE THE VEHICLE WITH MY KIDS IN THE CAR. I FEEL ITS A HUGE SAFETY ISSUE. ITS A TOTAL INCONVENIENCE TO HAVE TO KEEP GOING BACK TO THE DEALERSHIP AND DROP OFF MY VEHICLE. I HAVE THREE CHILDREN AND NEED A DEPENDABLE VEHICLE. LUCKILY WE WEREN'T INJURED BUT IM WORRIED THAT THE NEXT TIME IT HAPPENS AN INJURY COULD OCCUR. WHY HASN'T FORD LISTED THIS ISSUE IN THEIR TSB! *TR

IN OCT. 2008 I BOUGHT A NEW 2009 FORD FLEX. SOON AFTER I STARTED GETTING LOUD GRINDING NOISES IN THE BRAKES. THE DEALER SAID THAT THERE WAS A SERVICE ORDER ON THIS COMPLAINT AND CHANGED THE BRAKE PADS (TWICE). SINCE THEN THE PROBLEM HAS COME BACK INTERMITTENTLY AND THIS WEEK I HAD MY FOOT BARELY ON THE BRAKE PEDDLE WHEN I STARTED TO ACCELERATE AND THE GRINDING NOISE CAME AND THE BRAKES LOCKED UP MOMENTARILY. I HAVE BEEN IN TOUCH WITH FORD AND THEY DON'T SEEM TO HAVE ANY KNOWLEDGE OF THIS PROBLEM, AND I FEEL THE LOCAL DEALER IS NOT PURSUING A SOLUTION. LAST TIME I WAS IN THE DEALERSHIP I ASKED IF FORD HAD ANY ANSWER AND THEY JUST SAID "WE HAVE CHANGED THE PADS TWICE". THE PROBLEM IS INTERMITTENT AND HARD TO PIN DOWN AS TO WHEN AND HOW OFTEN IT HAPPENS, BUT IS NOISY WHEN IT DOES AND ANNOYING. THE DEALER SAID "IT IS NOT A SAFETY ISSUE" I WONDER WHEN THEY LOCKED UP A COUPLE DAYS AGO. LAST INCIDENT IS BELOW. THANK YOU *TR

BRAKE GRINDING AND SHUDDERS FROM FRONT DISC BRAKES AND SOMETIMES REAR DISK BRAKES. FORD HAS A LONG ONGOING PROBLEM WITH THE DISK BRAKES ON FORD FLEX'S. SEVERAL TSB'S HAVE BEEN ISSUED. HOWEVER IT SEEMS LIKE NO PARTS ARE BEING SENT TO DEALERSHIPS TO TAKE CARE OF THIS PROBLEM. *TR

TL*THE CONTACT OWNS A 2009 FORD FLEX. THE CONTACT STATED THAT THE BRAKES WERE GRINDING. THE CONTACT HAD TO REPLACE THE BRAKE PADS AND THE ROTORS FOUR TIMES. THE CONTACT ALSO STATED WHILE DRIVING IN THE RAIN ALL OF THE LIGHTS START FLICKERING AND A BURNING SMELL WAS EMITTED INTO THE VEHICLE. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHO DIAGNOSED THAT WATER OVERFLOWED INTO THE ENGINE BECAUSE OF THE WAY THE VEHICLE WAS DESIGNED CAUSING THE SERPENTINE BELT TO COME OFF, AS A RESULT THE BATTERY WAS OVER HEATING AND THE VEHICLE WAS LOOSING POWER. THE BATTERY HAD TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT DID NOT OFFER ANY ASSISTANCE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 22,000 AND THE CURRENT MILEAGE WAS 44,000.

TL*THE CONTACT OWNS A 2009 FORD FLEX. THE CONTACT STATED THAT THERE WAS AN OIL LEAK ON THE REAR OF THE ENGINE. THE ENGINE WAS REMOVED AND THE LEAK WAS REPAIRED BY THE DEALERSHIP. THE AIR CYLINDER THAT LIFTED THE THIRD ROW SEATS WAS DEFECTIVE AND HAD TO BE REPLACED. THE REAR HATCH OPENED ON ITS OWN FIVE TIMES; THE DEALER REALIGNED THE DOOR TO REMEDY THE PROBLEM. THE REAR MAIN OIL SEAL FAILED SO IT WAS ALSO REPLACED AT THE DEALERSHIP. THE BRAKES FAILED TO STOP THE VEHICLE EFFECTIVELY. WHEN THE VEHICLE WAS TAKEN TO THE DEALERSHIP, THEY STATED THAT THE VEHICLE WAS FINE. THE BATTERY WAS DEFECTIVE AND WAS REPLACED. THE TRANSMISSION EXCESSIVELY SHIFTED INTO GEAR WHEN DOWN SHIFTING, CAUSING THE VEHICLE TO JERK AND SHAKE. THE DEALER STATED THAT THEY COULD NOT FIND A PROBLEM WHEN THEY INSPECTED THE VEHICLE. THE ENGINE MADE A POPPING NOISE WHEN HE ACCELERATED FROM A STOP. THE DOOR MOLDING AND WINDOW MOLDING SILLS BECAME WARPED. LASTLY, ONE OF THE TIRES (THE CONTACT COULD NOT RECALL WHICH ONE) BLEW AND THE SIDEWALL SEPARATED; HE REPLACED THE TIRE AT HIS EXPENSE. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT ONCE THE VEHICLE LEFT THE MANUFACTURING PLANT, IT WAS THE DEALERSHIP RESPONSIBILITY AND OFFERED NO ASSISTANCE. THE CURRENT MILEAGE WAS 15,283. THE FAILURE MILEAGE WAS 7,526. THE BATTERY HAD TO REPLACED. UPDATED 12/30/10*JB

TL*THE CONTACT OWNS A 2009 FORD FLEX. WHILE THE VEHICLE WAS PARKED, THE CONTACT OBSERVED THAT THE BRAKE PEDAL EXTENDED TO THE FLOOR. THE FAILURE ALSO OCCURRED WHEN THE VEHICLE WAS IN MOTION; HOWEVER, HE WAS ABLE TO STOP THE VEHICLE AFTER RAPIDLY APPLYING PRESSURE TO THE BRAKE PEDAL. THE VEHICLE WAS TOWED TO THE DEALER APPROXIMATELY 4 TIMES TO HAVE IT DIAGNOSED; HOWEVER, THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE. THE DEALER HAS ATTEMPTED TO DIAGNOSE THE FAILURE FOR TWO WEEKS. THE DEALER ALSO CONFIRMED THAT THEY WOULD NOT REPAIR THE VEHICLE ALTHOUGH THE WARRANTY IS VALID. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 126000.

PURCHASED VEHICLE NEW IN MAY 2009. VEHICLE HAD TO GO IN FOR BRAKE REPAIRS 10 DAYS AFTER I TOOK DELIVERY OF THE VEHICLE. BRAKES HAVE BEEN REPAIRED A TOTAL OF 7 TIMES SINCE I PURCHASED IT. ON SEPT 18, 2013 THE BRAKES SEIZED WHEN I ATTEMPTED TO STOP AT A TRAFFIC LIGHT. *TR