Ford Recalls Over 270,000 SUVs For Potential Brake Line Defect

Ford Motor Company has initiated a voluntary recall for approximately 273,789 vehicles in the United States over a manufacturing defect involving the front brake lines. The recall affects 223,315 units of the 2022 to 2024 Ford Expedition and 50,474 units of the Lincoln Navigator that were manufactured between April 15, 2021, and November 20, 2024.

According to he report filed by Ford to NHTSA, Front brake lines in the affected vehicles may be in contact with the engine air cleaner outlet pipe. This can result in a brake line leak. 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.

The front brake line may have been bent during the engine installation process at Ford’s final assembly plant. The customer may experience an increase in pedal travel. With continued driving, a leaking brake line will cause the brake fluid level in the master cylinder reservoir to decrease. When the level reaches the “Low” mark on the reservoir, the red brake warning indicator light will illuminate.

The defect was first reviewed by Ford’s Critical Concern Review Group in February 2025 after an increase in brake-related warranty claims for 2022 Navigator models. Following a detailed investigation, a change was implemented at the plant on November 20, 2024, to prevent the brake lines from being bent during assembly. By April 2025, 45 warranty claims and several field and customer reports had been linked to this issue, although no crashes or injuries have been reported so far.

To dela with the issue, Ford's authorized dealers will inspect the brake lines for proper routing and clearance and will replace the brake line or air cleaner outlet pipe as needed, free of cost. Customers who already paid for repairs related to this issue may be eligible for reimbursement.