Ford Recalls 274,000 SUVs for Brake Issue
Overview of the Recall
Ford Motor Company is recalling nearly 274000 full-size SUVs across its Ford Expedition and Lincoln Navigator lines in the United States. The action follows analysis by the National Highway Traffic Safety Administration indicating that an installation defect could allow the front brake line to contact the engine air cleaner outlet pipe, potentially resulting in brake fluid leakage and reduced braking performance.
Recall Details and Affected Models
- Model Coverage: 223315 Ford Expeditions and 50474 Lincoln Navigators.
- Model Years: 2022 through 2024.
- Defect Rate: Ford estimates that approximately 1 percent of vehicles in this population exhibit the condition, based on internal warranty and field data.
- Warranty Reports: As of April 17, 2024, Ford had received 45 reports of front brake line leaks. No crashes or injuries have been attributed to this issue.
Technical Analysis of Brake Line Defect
The affected vehicles use a high-pressure hydraulic brake system conforming to SAE J1703 standards and equipped with a cast-aluminum air cleaner outlet. During assembly, misalignment or inadequate clamp torque can allow the steel brake line to rub against the outlet pipe under engine vibration. Over time, this cyclical rubbing can abrade the brake line coating, creating microperforations that permit fluid escape.
Brake fluid leakage reduces hydraulic pressure in the master cylinder, increasing pedal travel and requiring greater force for stopping. In severe cases, sufficient fluid loss can trigger the red brake warning indicator and compromise stopping distances at highway speeds.
Owner and Dealer Next Steps
- Ford and Lincoln dealers will inspect the front brake line routing and the air cleaner outlet pipe on recalled vehicles.
- If interference is detected, technicians will replace the brake line and/or the air cleaner outlet pipe, or apply revised mounting hardware, at no charge to owners.
- Dealer notification began on May 22, 2024, and owner notification letters will be mailed between May 26 and May 30, 2024.
- Vehicle owners can verify recall status using the NHTSA recall lookup or Ford’s online recall portal with campaign number 25S47.
Industry Context and Expert Perspectives
The recall comes amid heightened scrutiny of automotive component reliability by U.S. regulators. The NHTSA has increased mechanical integrity audits following several high-profile brake and steering recalls across multiple OEMs.
“Brake line abrasion issues like this are rare but can have serious safety implications if not caught early,” says Dr Robert Ellis, a veteran automotive safety engineer with SAE International. “Manufacturers are improving assembly validation to prevent minor misalignments from evolving into fluid-leak scenarios.”
According to recent industry data, overall U.S. vehicle recalls rose 12 percent in the past year, driven by tighter standards and more rigorous testing protocols. This trend underscores the importance of proactive quality control and prompt remedial actions by automakers.
Impacted owners should adhere to dealer instructions and monitor brake performance. Addressing this defect promptly ensures restoration of full braking capacity and compliance with federal safety regulations.