Ford recalls over 273K Expeditions and Navigators due to brake line issue

Ford has recalled over $273,000 SUVs due to an issue with leaking brake lines that could lead to longer braking times and potential crashes.

According to Ford, an issue with the brake lines could make it take longer for drivers to come to a complete stop, and increases the risk for crashes. So far, the Michigan-based company has not received reports of accidents or injuries.

Here’s what you need to know about NHTSA recall no. 25V-314 and what to do if you have a recalled vehicle.

The recall includes 273,789 vehicles, per a report shared on the National Highway Traffic Safety Administration (NHTSA) website.

According to Ford, the issue is caused when the vehicle’s front brake lines come into contact with the engine air cleaner outlet pipe. This can lead to 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,” Ford said in the announcement. “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 said in the recall announcement that the front brake line may have been bent during the engine installation process at Ford’s final assembly plant.

Ford said the company will notify impacted customers via mail and let them know to take their vehicles to a Ford or Lincoln dealer to inspect the front brake line. The dealer will replace the brake line or air cleaner outlet pipe for free if needed.

Ford has also said drivers who have already paid for the repairs may be eligible for reimbursement.

Ford plans to let dealers know about the issue on May 14, and will mail notification to drivers between May 26 and May 30.

The investigation into the issue began in late February 2025, Ford said. There had been an increase in brake system warranties on the 2022 Navigator vehicles. Someone then alerted Ford’s Critical Concern Review Group about front brake line leaks.

Between March 2025 and April 2025, Ford reviewed assembly plant records and investigated the assembly process. 

The company found that Ford’s Kentucky Truck Plant changed the radiator hose stowage process during engine decking. The change was made in November 2024 to prevent the brake line from being bent. According to Ford, Expedition and Navigator vehicles made before this change could possibly experience a bent brake line during the engine installation process. 

Saleen Martin is a reporter on USA TODAY's NOW team. She is from Norfolk, Virginia – the 757. Email her at sdmartin@usatoday.com.