Ford, America's biggest carmaker, recalls 274,000 SUVs over faulty brakes
America's largest car manufacturer has recalled 273,789 SUVs due to an issue that may cause a loss of brake function while driving which in turn increases the risk of a crash.
Ford issued the alert for 223,315 Expeditions and 50,474 Navigators that were produced between 2022 and 2024.
The recall comes after it was found that the front brake lines in the now-recalled cars 'may be in contact' with their engine air cleaner outlet pipe due to a potential installation defect, according to documents published by the National Highway Traffic Safety Administration (NHTSA).
The fault can result in a brake fluid leak and/or a loss of brake function.
Impacted drivers may experience an increase in pedal travel, NHSTA documents warned, meaning that the pedal would need to be pressed harder in order to sufficiently apply the brakes.
If there's a leaking brake line, the fluid level will decrease over time - potentially causing the red brake warning indicator to light up.
Ford is not aware of any accidents or injuries related to the recall and expects just one per cent of the recalled vehicles to have the defect.
However, at least 45 owners have reported front brake line leaks since April 17.
Impacted owners are expected to be notified of the recall via letter starting from May 26, which will include instructions on how they should proceed.
Dealers at Ford or Lincoln facilities will inspect the front brake line for proper clearances, proper routing and retention.
The recall reads: 'The dealer will replace the brake line or air cleaner outlet pipe as required. There will be no charge for this service.'
Between March and April 2025, Ford looked into operations at their Kentucky Truck Plant and found that on November 20, 2024, the plant had changed the way they stored the radiator hose during engine installation.
The change was made to stop the brake line from getting bent and to ensure everything fit properly.
The team discovered that before the change, some Expedition and Navigator vehicles might have had a problem.
During engine installation, the radiator hose could accidentally catch and bend the right front brake line.
If that happened, the brake line might not be routed correctly and could rub against another engine part - the air cleaner outlet pipe - which could cause damage over time.
NHSTA stated: 'As of April 17, 2025, Ford is aware of 45 warranty reports of a front brake line leak received between November 4, 2022 and April 8, 2024.
'Additionally, Ford is aware of two field reports received on August 4, 2022 and April 10, 2025, and two Customer Service Reports received on June 26, 2024 and August 28, 2024.'
Ford issued a similar recall in April over fears that vehicles could burst into flames on the road.
The recall included the 2020-2022 Ford Escape and 2021-2023 Ford Bronco Sport.
NHTSA officials noted that the 33,576 vehicles were actually part of two previous recalls, which failed to correctly fix the damage.
The fuel injector is a key piece of any gas-powered automobile, acting as a tiny sprinkler that sprays gasoline into the car's engine.
When this part of the vehicle is cracked, gas can start dripping into other parts of the engine, which can get extremely hot when the car is running.
If the engine parts exposed to gas are too hot or if there is even a tiny spark from the car's electrical systems, the gasoline could ignite triggering a blaze.
Drivers affected by this recall should have received a notice in the mail around April 24.
Ford will be fixing the cracks, plus updating each car's powertrain control module software free of charge.
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