Ford Motor Company has announced a major safety recall involving 273,789 SUVs. The issue is linked to a brake line defect that may lead to longer stopping times and a higher risk of accidents. This recall applies to the 2022–2024 Ford Expedition and the 2022–2024 Lincoln Navigator. The vehicles were made at Ford’s Kentucky Truck Plant, and the problem is traced to an error during assembly.
Why the Recall Was Issued
The front brake line in some SUVs was installed in a way that causes it to rub against the engine air cleaner outlet pipe. Over time, this contact can lead to a brake fluid leak. A loss of brake fluid can reduce pressure in the braking system. As a result, drivers may notice that it takes longer to stop their vehicle. In severe cases, complete brake failure could occur.
This poses a serious safety risk, especially during emergency stops. The more fluid that leaks, the worse the braking response becomes.
Vehicles Affected by the Recall
According to the National Highway Traffic Safety Administration (NHTSA), the recall includes:
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Most 2022–2024 Ford Expedition models
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50,474 units of the 2022–2024 Lincoln Navigator
Owners can check if their SUV is part of the recall by visiting the official NHTSA recall website and entering their Vehicle Identification Number (VIN).
How the Issue Happened
The problem began during engine installation. Ford found that some brake lines were bent in a way that allowed them to touch the air cleaner pipe. This happened at the Kentucky Truck Plant during vehicle assembly. In November 2024, Ford made changes to the assembly process to prevent the defect in future builds. However, vehicles built before that change are now at risk.
This assembly flaw went unnoticed for months. In early 2025, Ford’s internal systems picked up a spike in warranty claims related to brake issues on certain 2022 Lincoln Navigators. These reports triggered a deeper review by the company’s Critical Concern Review Group.
Between March and April 2025, Ford’s team studied assembly records and linked the increase in brake problems to the bent brake line installation on earlier builds.
What Drivers Should Do Now
Ford will send recall notices by mail between May 26 and May 30, 2025. In the meantime, SUV owners can take steps to stay safe:
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Call your Ford or Lincoln dealer to schedule a free inspection.
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A technician will examine the front brake line to see if it’s touching or rubbing against the engine air cleaner pipe.
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If needed, the technician will replace the brake line and/or the air cleaner outlet pipe—at no cost to you.
If you have already paid for brake repairs due to this issue, you may be eligible for reimbursement. Keep your repair records and bring them when you visit the dealership.
Signs of Brake Trouble
Drivers of affected models should pay attention to the following signs:
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Longer stopping distances
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Brake warning lights
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Soft or spongy brake pedal
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Unusual noises when pressing the brakes
If you notice any of these problems, do not delay—have your vehicle inspected as soon as possible.
Why This Recall Matters
This is not the first time Ford has issued a large recall due to brake system issues. In 2022, Ford recalled over 1 million vehicles because of problems with the brake booster. As car technology becomes more advanced, safety recalls are becoming more common, and it is important for car owners to respond quickly.
Brakes are one of the most critical safety features on any vehicle. A brake fluid leak may start slowly but can turn into a dangerous failure if left unchecked.
Ford’s Response
Ford has acted swiftly to address the problem. Dealers will receive service instructions by May 14, 2025, so they can begin repairs as soon as owners start bringing vehicles in.
A Ford spokesperson said, “We take safety seriously and are working quickly to fix the issue. Our customers’ trust and safety are our top priorities.”
This large recall reminds all drivers of the importance of vehicle maintenance and recall awareness. If you own a 2022–2024 Ford Expedition or Lincoln Navigator, check your VIN right away. If your vehicle is affected, don’t wait—book a service visit now.