Ford recalls nearly 275,000 Navigator and Expedition SUVs over possible brake damage

Ford Motor is issuing a recall for 273,789 Lincoln Navigator and Ford Expedition vehicles due to a potential safety issue with the front brake line. The National Highway Traffic Safety Administration announced the recall on May 9, citing concerns that a poorly installed brake line could lead to reduced brake function, increasing the risk of a crash.

The affected vehicles may have a bent brake line that could come into contact with the engine air cleaner outlet pipe. This contact could result in damage to the outlet pipe, leading to a brake fluid leak. As a result, the front brakes of the vehicle may cease to function properly, posing a safety hazard on the road.

According to recall documents, a brake line leak could cause a longer brake pedal travel and a reduction in the rate of deceleration. If there is a rapid loss of brake fluid or the fluid is completely depleted, it can increase the stopping distance of the vehicle, thereby raising the risk of a crash.

Fortunately, Ford has not received any reports of accidents or injuries related to the faulty brake line. The recall affects certain models of the Lincoln Navigator and Ford Expedition manufactured between 2022 and 2024.

The issue with the bent brake line is believed to stem from a faulty assembly process during the engine installation at Ford’s Kentucky Truck Plant. An internal review of plant records revealed that modifications were made to the engine installation process in November to prevent damage to the brake line. Unfortunately, the vehicles included in the recall were manufactured before these modifications were implemented.

In the event of a brake fluid leak, drivers may experience an increase in pedal travel or notice a decrease in brake fluid levels in the master cylinder reservoir. A red brake warning indicator light will illuminate once the fluid levels drop to a dangerously low level.

To address the problem, Ford dealers will inspect the front brake line and replace it or the air cleaner outlet pipe if necessary, at no cost to the owners. Notifications will be sent to affected owners on May 26, 2025. Owners can also contact Ford customer service at 1-866-436-7332 for more information. The National Highway Traffic Safety Administration Vehicle Safety Hotline is available at 888-327-4236 for any concerns related to the recall.