Ford Motor Company has issued multiple recalls affecting hundreds of thousands of vehicles across its lineup. The most significant recall involves nearly 274,000 SUVs due to potential brake failure issues that could increase crash risks. If you own a Ford vehicle, understanding these recalls and taking prompt action is crucial for your safety and that of others on the road.
Ford’s Kentucky Truck Plant where many of the affected vehicles were manufactured
Recent Ford Recalls: Brake Issues and Safety Concerns
On May 9, 2025, Ford issued several recalls affecting multiple vehicle models. The largest and most concerning recall involves 273,789 Ford Expedition and Lincoln Navigator SUVs from model years 2022-2024 due to potential brake failure issues.
According to the National Highway Traffic Safety Administration (NHTSA), the front brake line in these vehicles “may be in contact” with the engine air cleaner outlet pipe due to an installation defect. This contact can cause brake fluid leaks, potentially resulting in reduced braking ability or complete loss of front brake function.
“A brake line leak may cause a longer-than-expected brake pedal travel and result in a reduction in the rate of deceleration. If there is a rapid loss of brake fluid or the brake fluid is completely depleted, this can extend the distance required to stop the vehicle, increasing the risk of a crash,” states the NHTSA in its report.
While Ford has received 45 warranty reports of front brake line leaks, the company states it is not aware of any accidents or injuries related to this issue. However, the safety risk remains significant, as brake failure can lead to serious accidents.
Affected Models and Production Years
The major brake-related recall affects the following Ford vehicles:
- 2022-2024 Ford Expedition SUVs (223,315 vehicles)
- 2022-2024 Lincoln Navigator SUVs (50,474 vehicles)
Additionally, Ford issued three smaller recalls on the same day affecting:
- 2024 Ford Bronco (2,002 units) – Child safety lock issues
- 2024 Ford Bronco and Ranger (46 units) – Missing driver’s seat bolts
- 2025 Ford F-150 (9,181 units) – Loose steering components
Ford estimates that only 1% of the recalled Expedition and Navigator vehicles actually have the brake line defect, but all vehicles within the specified model years need inspection to ensure safety.
Safety Risks Identified by Ford and NHTSA
The primary safety concern with the brake line recall involves potential brake failure while driving. According to NHTSA documents, owners may experience:
Warning Signs
- Increased brake pedal travel (pedal feels “soft” or goes further down than normal)
- Reduced braking effectiveness
- Red brake warning indicator light on dashboard
- Visible brake fluid leaks under the vehicle
Potential Consequences
- Extended stopping distance
- Partial loss of braking ability
- Complete front brake failure in severe cases
- Increased risk of collision
The issue stems from the front brake line potentially being bent during the engine installation process at Ford’s Kentucky Truck Plant. This manufacturing defect allows the brake line to contact the engine air cleaner outlet pipe, causing wear and eventual fluid leakage.
Warning: If you experience any of these symptoms while driving, reduce speed immediately, maintain extra distance from other vehicles, and have your vehicle towed to a Ford dealer rather than continuing to drive it.
Ford’s Response and Repair Plans
Ford has developed a comprehensive plan to address these safety concerns. The company will:
- Inspect the front brake line of all affected vehicles
- Replace the brake line or air cleaner outlet pipe if necessary
- Perform all repairs at no cost to vehicle owners
- Mail notification letters to all registered owners between May 26-30, 2025
Ford has already notified its dealer network, with dealer notifications beginning on May 15, 2025. The company has also implemented a modification to its manufacturing process at the Kentucky Truck Plant as of November 20, 2024, to prevent this issue in newly produced vehicles.
“Through this investigation, Ford’s Critical Concern Review Group discovered that Ford’s Kentucky Truck Plant had modified the radiator hose stowage process during engine decking. This modification was done to prevent the brake line from being bent and was made starting on November 20, 2024 to ensure proper clearances were met,” the recall documents state.
What Vehicle Owners Should Do
Check If Your Vehicle Is Affected
- Locate your Vehicle Identification Number (VIN) – found on your registration, insurance card, or on the driver’s side dashboard visible through the windshield
- Visit Ford’s recall lookup website or the NHTSA website
- Enter your VIN to see if your vehicle is included in any active recalls
- If affected, schedule a service appointment with your local Ford dealer as soon as possible
Check Your Vehicle’s Recall Status Now
Don’t wait for a letter – find out immediately if your Ford vehicle is affected by this or any other recall.
Temporary Precautions
If you own an affected vehicle but haven’t had it repaired yet:
- Monitor your brake pedal feel – if it seems “soft” or travels further than normal, have your vehicle towed to a dealer
- Watch for the red brake warning light on your dashboard
- Check for fluid leaks under your vehicle, particularly near the front wheels
- Maintain extra following distance when driving
- Schedule your repair appointment as soon as possible
Contact Information: For questions about this recall, contact Ford Customer Service at 1-866-436-7332. Ford’s number for this recall is 25S47. You can also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153).
Historical Context of Ford Recalls
This latest recall is part of a broader pattern of quality control challenges facing major automakers. Ford has issued several significant recalls in recent years:
| Year | Models Affected | Issue | Vehicles Recalled |
| 2023 | Explorer, F-150, Mustang Mach-E | Rearview camera display failure | 382,000 |
| 2022 | F-150 | Windshield wiper motor failure | 453,000 |
| 2021 | Explorer | Roof rail detachment risk | 661,000 |
| 2020 | F-150 | Transmission shift problems | 292,000 |
While recalls are common across the automotive industry, Ford has faced particular scrutiny over quality control issues in recent years. The company has responded by implementing new quality assurance processes and increasing investment in manufacturing improvements.
Industry experts note that the increasing complexity of modern vehicles, with advanced electronics and safety systems, has contributed to higher recall rates across all manufacturers. However, mechanical issues like the brake line defect in this latest recall highlight the continued importance of basic quality control in vehicle assembly.
Taking Action on Ford Recalls
Vehicle recalls are issued to address safety concerns and protect drivers, passengers, and others on the road. While they may be inconvenient, having your vehicle repaired promptly is essential for your safety.
If you own a Ford vehicle, particularly a 2022-2024 Expedition or Navigator, check your recall status immediately using the resources provided. Ford dealers are prepared to inspect and repair affected vehicles at no cost to owners.
Schedule Your Free Recall Repair
Don’t delay addressing this important safety issue. Contact your local Ford dealer to schedule your free inspection and repair.
Or call Ford Customer Service: 1-866-436-7332
Remember that all recall-related repairs are provided free of charge, and many dealers offer loaner vehicles or shuttle services while your vehicle is being serviced. Your safety on the road depends on addressing these critical recalls promptly.
