Steve,
I just checked and found we purchased ours in November of 2004, so we’d have an early generation of TBC, as well.
But since my problem comes at high speeds, (plus we have two alternators, so it’s not likely a voltage or current problem,) I’m guessing it’s a trailer problem.
So you lose braking, all together, when near idle speeds? What a pain that must be.
Keep on Ford. I’m guessing that they will relent, eventually. Just tell them you’ve been posting about this problem for a while, and will simply continue to do so. They seemed to take a lot of stock in my filling out a “Customer Satisfaction” survey, after I bought my truck. Hearing that a disgruntled customer’s loose on the Internet might persuade them that just giving you the new TBC would be worthwhile!
Steve