Hope this helps. I can't find a recall on this fault. But it may be worth your while talking to ford?
FRONT BRAKE ROUGHNESS - SHUDDER WHILE BRAKING
TECHNICAL SERVICE BULLETIN
Reference Number(s): 05-21-19, Date of Issue: October 31, 2005
FORD:2004-2005 F-150
Superceded Bulletin(s): 05-6-21, Date of Issue: April 4, 2005
Related Ref Number(s): 04-15-1, 04-26-11, 05-21-19, 05-5-2, 05-6-21
ARTICLE BEGINNING
DESCRIPTION
FRONT BRAKE ROUGHNESS - SHUDDER WHILE BRAKING
ISSUE
NOTE:This article supersedes TSB 05-6-21 to add new parts and update Service Procedure.
Some 2004/2005 F-150 vehicles built before 11/29/2004 may exhibit front brake roughness and or shudder while braking.
ACTION
Service the rack and pinion, rotors, and caliper assemblies as needed, based on vehicle build date and current part levels installed on the vehicle. Refer to the following Service Procedure.
SERVICE PROCEDURE
Vehicles built prior to 8/20/2003 require the replacement of the rack and pinion assembly if it has not been replaced. Refer to Workshop Manual, Section 206-03 and 211-02.
Determine if the vehicle has the old or new level rotors (Fig. 1 ).
Fig. 1: Old And New Level Rotors
If old level rotors, replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-00 for front rotor and caliper replacement.
NOTE:WHEN REPLACING THE ROTORS ON 4X2 UNITS, A NEW SPINDLE NUT IS REQUIRED.
If new level (47 fin) rotors are present, perform one (1) of the following:
If rotors are within minimum thickness specifications, machine the rotors using the Rotunda on vehicle brake lathe and the Rotunda adapter kit 201-R0093. Refer to the Workshop Manual, Section 206-00 for the correct on-vehicle brake lathe procedure.
If rotors are beyond machinable thickness, the front rotors must be replaced.
Install new service fix calipers.
NOTE:REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY
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Monday, November 10th, 2008 AT 9:37 PM