Ford Brake Fluid Leak May Lead to Loss of Brake Function in Certain Expedition, Lincoln Navigator Vehicles: NHTSA

Recalled vehicles may be more likely to cause rear-end crashes due to longer stopping distances from brake line damage.

Federal highway safety officials have announced a recall of 273,789 model year 2022 through 2024 Ford Expedition and Lincoln Navigator vehicles due to a potential defect in the front brake lines, which could increase the risk of an auto accident.

The U.S. National Highway Traffic Safety Administration (NHTSA) announced the Ford Expedition and Navigator recall on May 9, citing a manufacturing defect that may cause the front brake line to bend and rub against the engine air cleaner outlet pipe, potentially leading to damage.

The front brake line carries brake fluid to the wheels, helping to apply pressure when pressing the brake pedal. However, if it comes into contact with the engine air cleaner outlet pipe, which delivers filtered air to the engine for combustion, heat and friction may cause damage over time.

Officials warn that the damage could lead to brake fluid leaks, which may reduce braking performance and increase stopping distances. This heightened risk can lead to accidents, potentially resulting in serious injury or death.

Ford first became aware of the issue on February 27, after its Critical Concern Review Group (CCRG) received an increasing number of front brake line leaks and brake system warranty claims.

Over the following months, Ford conducted an internal investigation and found that the Kentucky Truck Plant (KTP) had modified its radiator hose stowage process on November 20, 2024. The change was made to improve clearances and prevent the radiator hose from catching and bending the brake line during assembly.

Ford’s Critical Concern Review Group determined that vehicles manufactured before this update may be at risk of brake line damage during engine installation, prompting the company to initiate a voluntary recall (PDF) on May 13.

While the safety recall report (PDF) does not indicate any accidents or injuries, Ford is aware of at least 45 warranty claims, two field reports and two customer service complaints related to the issue.

Customers will begin receiving notification letters on May 26, with instructions on how to receive a free inspection at a local dealer, and if necessary, replacement of the brake line or air cleaner outlet pipe.

Vehicle owners who have already had this repair performed at their own expense prior to receiving the recall notification may be eligible for reimbursement.

Customers may contact Ford customer service at 1-866-436-7332, or the company’s contact for this recall, Dusty Gardner, via email at dusty.gardner@dot.gov, and reference the recall number 25S47.

Owners with any additional questions may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-888-275-9171), or go to www.nhtsa.gov.