Dive Brief:
- Ford Motor Co. has recalled 123,611 pickup and SUV models for a condition where the brake master cylinder may develop an external leak or discharge fluid into the vehicle’s vacuum brake booster and impact braking performance, according to the National Highway Traffic Safety Administration.
- The recalled vehicles include 2017-2018 F-150 pickups, Expeditions and Lincoln Navigator SUVs equipped with the automaker’s 3.5L Ecoboost engine. An estimated 1% of the vehicles are believed to have defective master cylinders.
- Dealers will inspect the brake master cylinder and/or brake booster and replace any defective parts for free. Owner notification letters are expected to be mailed April 28.
Dive Insight:
A defective master cylinder may lead to a “substantial loss of brake fluid” which can result in reduced braking performance of the front wheels, according to the NHTSA.
The NHTSA notified Ford of the potential safety risk in January after receiving questionnaires from customers alleging brake fluid leakage into the brake booster on some 2017 Ford Expedition vehicles. The agency also inquired if the condition could be related to three prior recalls in May 2016, June 2020 and March 2022 that included earlier model F150s, Expeditions and Navigator SUVs for the same condition.
Ford presented the concerns to its Critical Concern Group for further review to comply with NHTSA’s request by Jan. 31, 2025.
A previous analysis of field data by Ford in November 2021 also identified an increase in failure rates of master cylinders in vehicles included in the second recall in June 2020.
The most recent review of field data conducted by Ford in February and March of this year also found an “elevated rate of warranty repairs” for brake fluid leaks on Expedition and Navigator SUV models produced in the first half of 2017, which followed the June 2016 recall. However, the automaker said it found no evidence of elevated warranty claims for F-150 pickups built within the same timeframe. Still, Ford’s Field Review Committee approved the recall on April 4 over safety concerns.
As of Jan. 31, 2025, Ford was aware of 73 warranty claims related to brake fluid leaks for Expedition or Navigator SUVs produced between February 1, 2017 and June 30, 2017, as well as 17 claims for F-150 pickups produced within the same timeframe.
The master cylinder was manufactured by Hitachi Astemo Americas. Earlier preventive actions taken by Hitachi after Ford’s first recall in May 2016 included the introduction of an automated process to remove imperfect threads from the master cylinder outlet port and a revised process for installing the rear cup seal to prevent damage. The improved part was introduced into production by Jan. 31, 2017, according to the NHTSA.
The supplier also introduced a production change after Ford’s second recall in June 2020 that included adding a silicone lubricant to the master cylinder seal to prevent damage.
Ford has issued 41 separate recalls so far this year, according to the NHTSA, which potentially includes over 1.2 million vehicles. In March, the company recalled 33,576 Bronco Sport and Escape models for fuel injectors that may crack and leak fuel onto hot engine components, which increases the risk of fire.
