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Ok I'll pile on here. I own an '07 F350 SC with 38,000 miles on it. I took the truck into the dealer when I first noted the problem at 34,600 mi.
The dealer replaced a few parts associated with the e-brake actuator. I drove it for a few more weeks thinking the problem was resolved but the brake eventually exhibited the same characteristics and even started to cause the axle to hop. I took it back again this time I had 37,500 miles and told the dealer that I feel it should still be covered since I noted the problem under warranty and they failed to correct it.
Good thing for me the service manager agreed. Anyways rust/corrosion was found on the caliper piston and the caliper was replaced. I though when I was under there I had seen TRW stamped onto the caliper.
It isn't like Ford picks lousy suppliers but talking to others it does seem to be a Ford problem. Not only do I not think it is limited to the 2000-2004 years but also carries over into the F-150 line. Design issue... most likely. Quality control? Probably not. Perhaps they are better shielded on other trucks or have more robust seals.
Incidentally the caliper that failed was the passenger rear.
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2007 F350 XLT 4x4 SC 6.0 PSD No Mods *Traded*
2011 F250 XLT/FX4 4X4 CC 6.7L PSD
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