Ford :: Escape XLT 2004 - Knocking / Pulsating In Brake Pedal


Jun 30, 2015

Having ABS issue with my 2004 Ford Escape XLT.

A bit of background information: every now and then (usually when decelerating from around 35-40mph), I will get a pulsating/knocking feeling from my brake pedal. At first, I thought it was the ABS, as I was told about a year ago that the ABS tone ring was broken. The more the problem manifested itself, the more I got to study it a bit. The pulsating/knocking in the pedal is usually accompanied by a very dry rubbing sound, and both the sound and the pulsating seem to be in direct relation to the motion of the wheels. I took it to the local garage this weekend and they recommended changing out the rear brakes - this made sense to me, as they haven't been changed out for as long as I have had the car.

Got the car back about an hour ago - on my way home, the pulsating came back when I was coasting into a stop light. The pulsating seems to have no affect whatsoever on the stopping distance of the car - a few times when it has happened, I have mashed the pedal, and the car comes to a quick stop just as you would want it to. After coming out of a complete stop, the brakes will work completely fine for a while - there seems to be no real rhyme or reason to what makes it happen.

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It is not quite as bad as before and does not happen until 68-70, 10 mph higher than before the tire change/balance. I have put my back wheels on the front and it is the exact same condition - this would remove tire and balance as the culprit (?). I also hear an audible hum.. kind of a pulsing sound at 50 mph+. This speeds up and slows down with my speed. For instance if I am going 70.. I hear it every half second, 50 mph I hear it less often. It is pretty faint, not a thump. It seems to be coming from the front but I can't pin-point it. I feel no tire play up/down/side/side.

What is the next step here? I'm going to get the rear toe fixed but this shouldn't be the cause of the pulse/wheel + pedal vibration. Vibration/sound doesn't happen when I am braking. No rubbing shield behind rotor.

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The kicker is, that was 35+k miles ago. Annoying, but three different dealerships never found anything and the service techs always made big eyes once you mentioned 85+ mph. "Oh, we can't legally replicate that"

Fast forward to now (meanwhile rotors changed, pads, tires) - the noise seems to appear randomly at lower speeds. It is also quieter (barely noticeable above 65).

Example from today - left dealership sporting new tires and a fresh proper 4-wheel alignment.

After accelerating to ~50 noticed the sound. Couple miles down the road stopped, made a U-turn - sound gone. Could not replicate for a while. Then had it twice on "straight and level" segments, seemingly random. On cruise control at 55 (hear it the best at that speed) sounds stay the same regardless of rpm (6-5-4 gear - no changes). Pulsating gets quicker-slower with speed. Very gently decelerated to 25 - noise went away completely, pedal to the metal back to 60 - no noise.

I'm at a complete loss as for what it can be. Turning makes no impact, no play on bearings (and I'm pretty sure those would have died long ago if it was them), rotors changed with zero impact, tires too.

Changes over time - got quieter and started to appear at lower speeds.

All stock except for H&R Sport springs on stock shocks. 88000 miles

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Now, here's my questions:

1. Can the rotors go bad and the brake pads be fine?
2. Should I go with a ceramic pad or stick with the OEM?

I'm just a female and don't want to be taken advantage of at the dealers. Cost is not an issue when purchasing a good product.

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This morning I let my car warm up for 40 minutes (15 minutes in park and 25 idling at the bus stop). The problem was no better. By knock I meant it feels like someone bumped the engine. My foot vibrates on the brake for a second. And when it changes into the highest gear, it shudders ( until I release or further press the gas pedal. The revs don't change while it is shuddering or knocking.

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I have made videos of it for them since it is so erratic it is hard to get it to do it for them. It will go days, weeks or even months without doing it, and then do it consistently for days and weeks. It seems to do it most when the weather is around 40-60 degrees and often when it is damp ... although this is not always the case. It will do it after you turn the car off for up to 30 seconds ... It will do it when you first start the car before you move.

By the way ... my son in law swears it is the little circular thing in the center of a speaker that vibrates back and forth with sound that is "popping". I suggested that to the dealer and they said that would be really surprising ... I told them that whatever it is its going to be surprising!

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