Ford Motor Company has issued a safety recall for more than 270,000 vehicles in the US linked to defects with the brakes that could increase the risk of a crash, the National Highway Traffic Safety Administration said on Wednesday.
The recall, which was filed with the federal agency last week, affects 223,315 Ford Expeditions and 50,474 Lincoln Navigators from model years 2022 through 2024.
According to Ford, a defect in the assembly process may have resulted in the front brake line making contact with the engine air cleaner outlet pipe, potentially leading to a brake line leak.
The company said the issue stems from a process at its Kentucky Truck Plant, where factory workers who were routing the radiator hose during engine installation may have caused the front brake line to bend.
This misalignment could mean the brake line isn’t positioned correctly and may end up rubbing against nearby engine parts.
Over time, this abrasion can wear down the material of the brake line, eventually causing it to weaken, crack or leak — which could lead to brake failure.
In simple terms, the brake line could get damaged from repeated contact with other components.
“A brake line leak may cause a longer than expected brake pedal travel and result in a reduction in the rate of deceleration,” the recall report states.
“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.”
Ford began investigating the issue in February after observing an increase in brake system warranty claims for 2022 model year Navigators.
The automaker later determined that a production modification introduced in November 2024 to improve radiator hose placement would prevent the brake line interference.
As of mid-April, Ford had received 45 warranty reports, two field reports and two customer complaints related to front brake line leaks.
However, the company noted that it is not aware of any accidents or injuries linked to the defect.
Owners of affected models will be notified by mail between May 26 and May 30. They will be instructed to bring their vehicles to a Ford or Lincoln dealership for inspection.
If necessary, dealers will replace the brake line and/or the air cleaner outlet pipe at no cost to the owner. Reimbursement will also be available for prior repairs made related to the issue.
Dealer notifications began Wednesday.
For more information, affected customers can contact Ford’s customer service line at (866) 436-7332.
