2022-2024 Ford Navigator and Expedition Brake Problem

Ford has issued a recall for certain 2022-2024 model year Navigator and Expedition vehicles due to a potential brake problem that could increase the risk of a crash. The issue affects the front brake line, which may have been damaged during the engine installation process at Ford's Kentucky Truck Plant.

According to Ford, the front brake line may have been bent or misrouted, causing it to come into contact with the engine air cleaner outlet pipe. This can result in a brake line leak, leading to reduced brake function and increased stopping distances. In severe cases, a rapid loss of brake fluid or complete depletion of the brake fluid reservoir can cause the vehicle to take longer to stop, increasing the risk of an accident.

Vehicle owners may experience symptoms such as increased pedal travel, and if the condition worsens, the red brake warning indicator light will illuminate when the brake fluid level in the master cylinder reservoir reaches the "Low" mark. Ford has reported 45 warranty claims related to front brake line leaks between November 2022 and April 2024, as well as two field reports and two customer service reports.

The problem was first identified by Ford's Critical Concern Review Group (CCRG) in February 2025, after noticing an increase in brake system warranty claims for certain 2022 model year Navigator vehicles. An investigation revealed that the issue was caused by a modification to the radiator hose stowage process during engine decking, which was implemented at the Kentucky Truck Plant to prevent brake line bending.

To address the issue, Ford will be inspecting and replacing the front brake line or air cleaner outlet pipe as necessary. Dealers have been notified, and owner notification letters are expected to be mailed on May 26, 2025. The recall affects certain 2022-2024 model year Navigator and Expedition vehicles, and owners can contact their local Ford dealer for more information.

Ford's recall number for this issue is 25S47, and the National Highway Traffic Safety Administration (NHTSA) campaign number is 25V-314. Fortunately, Ford has reported no accidents or injuries related to this condition. Vehicle owners are encouraged to contact their dealer as soon as possible to schedule an inspection and repair if necessary.