Dive Brief:
- Ford Motor Co. has recalled 312,000 pickup and SUV models for a loss of electronic power brake assist that can extend stopping distances and increase the risk of a crash, according to the National Highway Traffic Safety Administration.
- The recalled vehicles include the 2025 F-150, Ranger, Expedition, Bronco and Lincoln Navigator models built between November 2023 and June 2025. An estimated 1% of the recalled vehicles are suspected of having the defect.
- Ford is issuing an over-the-air software update to address the problem, but customers will have the option to schedule a service appointment at a dealer to have it performed, free of charge. Owner notification letters are expected to be mailed on Aug. 25.
Dive Insight:
Ford discovered the problem on May 14 after its Expedition/Navigator Rapid Response Team identified a vehicle that exhibited a loss of power brake assist and stored a diagnostic trouble code (DTC). The incident occurred on a management lease program vehicle, which offers lease deals to Ford employees.
From May through June, Ford used its connected vehicle database to identify other models with the stored DTC believed to be related to the brake issue. Investigators also reviewed vehicle data logs and met with drivers that experienced a sudden loss of power brake assist, excessive pedal travel or longer stopping distances in order to determine the scope of the problem.
Ford investigators concluded that the electronic brake booster (EBB) module may malfunction while driving or when the driver is using an advanced driver assist system feature. The majority of the recalled vehicles (218,000) are F-150 models.
An EBB replaces a vehicle’s traditional vacuum-operated brake booster with an electric motor to provide braking assist. These systems offer more precise stopping control and are also used in electric vehicles without a vacuum source.
According to the recall report, the EBB module is susceptible to changes in voltage that can lead to a momentary current spike exceeding the unit’s over-current monitoring threshold. The problem leads to the EBB motor shutting down and a loss of power brake assist. The units were sourced from Tier 1 supplier Bosch.
As of July 11, 2025, Ford is aware of 37 warranty claims related to a loss of brake assist received between March 13 and June 26, including one alleged low-speed crash. However, the automaker is not aware of any injuries.
Ford’s Field Review Committee approved the recall on July 18.
The revised EBB module software, which Ford expects will be available by the end of the month, will correct the unit’s response to voltage changes and ensure that it remains operational if any variations occur. According to the recall report, small changes in EBB voltage are considered to be normal, but happen infrequently.
Ford has issued 96 recalls since the start of 2025 for a host of vehicle problems, which is the highest number for any automaker in a single year, according to NHTSA data. The recalls potentially extend to over 6.4 million vehicles.
