Ford recalls nearly 274,000 SUVs due to brake defect
By lauraharris // 2025-05-20
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  • Ford has recalled 273,789 full-size SUVs (223,315 Expeditions and 50,474 Navigators) due to a brake defect that could result in reduced braking power or total brake failure, increasing the risk of crashes.
  • The problem stems from improperly installed front brake lines that could come into contact with the engine's air cleaner outlet pipe. Over time, this contact may cause brake fluid leaks and loss of braking performance.
  • The issue was traced to a production change at Ford's Kentucky Truck Plant in November 2024, where modifications to radiator hose positioning aimed to prevent brake line interference. Vehicles made before this change may still have the defect.
  • Ford has not linked the defect to any crashes or injuries, although there have been 45 warranty claims related to front brake line leaks. The company believes only one percent of affected vehicles have the defect.
  • Affected vehicle owners will be notified starting May 26 and can schedule free inspections and repairs at Ford or Lincoln dealerships. Dealers will inspect and fix the brake lines at no charge.
Ford Motor Company, the largest automaker in America, has issued a major recall affecting 273,789 full-size SUVs due to a brake defect that could lead to reduced braking performance or total brake failure while driving, significantly increasing the risk of a crash. According to the documents released by the National Highway Traffic Safety Administration (NHTSA), the recall includes 223,315 Ford Expeditions and 50,474 Lincoln Navigators manufactured between 2022 and 2024. The issue is a front brake line that may have been improperly installed, potentially making contact with the engine's air cleaner outlet pipe. Over time, this contact could cause damage to the brake line, leading to leaks in brake fluid and loss of braking power. Ford traced the defect back to a change in production procedures at its Kentucky Truck Plant. On Nov. 20, 2024, the plant modified how it positioned radiator hoses during engine installation to prevent interference with the brake lines. However, vehicles built before this change may have suffered from misrouted brake lines, increasing the chance of contact with the air cleaner pipe and potential long-term wear or rupture. (Related: Ford recalls electric version of iconic Mustang muscle car, citing manufacturing defect.) Drivers of the affected vehicles may notice increased pedal travel, requiring more force to stop the vehicle and illumination of the red brake warning light, indicating a drop in brake fluid. Ford claims no crashes or injuries have been linked to the issue, but at least 45 warranty claims involving front brake line leaks have been filed as of April 17. Additional complaints include two field reports and two customer service reports spanning from mid-2022 to early 2025. As a response, Ford will begin notifying affected customers by mail starting May 26, with instructions on how to schedule a free inspection and repair at a Ford or Lincoln dealership. Dealers will inspect the front brake lines for clearance and correct routing. If necessary, they will replace the brake line or air cleaner outlet pipe at no cost to the owner.

Ford has recalled hundreds of thousands of vehicles due to faulty parts over the past six months

The latest recall adds to a growing list for the $38 billion company. In April, Ford recalled more than 33,000 of its vehicles over a dangerous defect that could cause them to catch fire while on the road. The NHTSA flagged a cracked fuel injector issue in certain 2020-2022 Ford Escapes and 2021-2023 Ford Bronco Sport models that can allow gasoline to leak onto hot engine components, potentially leading to spontaneous fires, even without a spark. The vehicles affected were previously subject to two earlier recalls, which failed to fully resolve the problem The fuel injector is a critical engine component that sprays gasoline into the engine's combustion chamber. In the recalled vehicles, a crack in this part may allow gas to leak into surrounding areas under the hood – areas that can reach temperatures between 300 F and 800 F. At these temperatures, gasoline may ignite without any electrical failure or spark, through a process known as auto ignition – which occurs when fuel combusts purely from high heat. Such fires could start small but spread rapidly in the confined, oxygen-rich space under a vehicle's hood, potentially engulfing the entire car within minutes. Meanwhile, in January, Ford issued a recall for 272,817 vehicles across the U.S. due to concerns over potential battery failures. This recall included 2021-2023 Ford Bronco Sports and 2022-2023 Ford Maverick trucks. The issue involved the 12-volt battery, which may degrade over time and unexpectedly fail, potentially causing a loss of power to critical electrical systems, including the hazard lights. Just weeks earlier, on Dec. 31, Ford had already recalled certain 2020-2024 Ford Escape and Lincoln Corsair models for similar battery-related problems. Watch this video discussing low brake fluid. This video is from the JMTC Performance channel on Brighteon.com.

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Ford drastically cuts EV factory workforce as electric car sales plummet.

Sources include: DailyMail.co.uk 1 DailyMail.co.uk 2 Brighteon.com
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