Overview

• Ford's recall impacts 273,789 SUVs, including 223,315 Expeditions and 50,474 Navigators from model years 2022–2024.
• A defect in assembly at Ford's Kentucky Truck Plant caused brake lines to bend and contact the engine air cleaner outlet pipe, leading to potential brake fluid leaks.
• Ford began investigating the issue in February 2025 after noticing an increase in warranty claims, tracing the defect to a November 2024 manufacturing process change.
• No accidents or injuries have been reported, but Ford has logged 45 warranty claims and two customer complaints related to brake line leaks as of mid-April 2025.
• Dealers will inspect and replace affected components at no cost, with owner notifications scheduled for mailing between May 26 and May 30, 2025.