Ford Motor Co. has recently initiated a significant safety recall, impacting over 312,000 vehicles across the United States. This recall addresses a critical defect within the electronic power brake assist system, a component vital for ensuring safe stopping distances. For owners of affected 2025 F-150, Ranger, Expedition, Bronco, and Lincoln Navigator models, understanding the nuances of this recall is paramount.
At Consumer Reports, our mission is to empower you with thorough, objective, and reliable information to safeguard your automotive experiences. This detailed article aims to provide a comprehensive overview of Ford’s latest recall, breaking down the technical specifics, the potential risks involved, and the steps Ford is taking to rectify the situation. Our commitment is to present the facts clearly, ensuring you have all the necessary information to act decisively and protect yourself and your family on the road.
The implications of a compromised braking system cannot be overstated. A defect leading to extended stopping distances directly correlates with an increased risk of collisions, highlighting the urgency and seriousness of this situation. We will delve into the specifics of who is affected, what the core problem entails, and how this issue was identified, setting the stage for a deeper understanding of this crucial safety alert.
1. **The Expansive Scope of the Recall: Affected Models and Vehicle Count**This Ford recall is substantial, encompassing a total of 312,120 vehicles across various popular 2025 model-year vehicles within the United States. The breadth of this recall underscores the importance for a wide range of Ford and Lincoln owners to pay close attention to the details provided.
Specifically, the recall targets certain 2025 F-150, Ranger, Expedition, Bronco, and Lincoln Navigator models. The vast majority of affected vehicles are the F-150, accounting for an estimated 217,969 units. This highlights the widespread nature of the issue across one of Ford’s most popular and best-selling trucks.
Beyond the F-150, the recall also impacts 20,552 Ford Ranger pickups, 39,913 Ford Bronco SUVs, and 26,582 Ford Expedition SUVs. For luxury vehicle owners, 7,104 Lincoln Navigator SUVs from the 2025 model year are also included in this important safety action. These numbers collectively paint a clear picture of the significant population of vehicles potentially at risk due to this defect.
It is important for owners to remember that these vehicles were manufactured between November 2023 and June 2025. While the recall covers a large number, Ford estimates that only about 1% of the recalled vehicles are actually suspected of having the specific defect. Nevertheless, the potential for a serious safety hazard necessitates a recall for all potentially impacted units to ensure comprehensive safety.
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2. **Unpacking the Core Issue: The Electronic Power Brake Assist Defect**At the heart of this recall lies a defect within the electronic power brake assist (EBB) system. This system is a fundamental component in modern vehicles, responsible for providing assistance to the driver when braking, effectively reducing the physical effort required to slow or stop the vehicle. A malfunction in this system directly compromises a vehicle’s ability to brake effectively.
The electronic power brake assist system, and specifically the EBB module, may malfunction, leading to a loss of power brake assist. This means that when a driver presses the brake pedal, the usual assistance they expect may not be present, making the pedal feel much stiffer and requiring significantly more force to achieve the desired braking effect.
This loss of power brake assist is not merely an inconvenience; it is a critical safety concern. Without the electronic assistance, the vehicle’s stopping distances can be extended considerably. In emergency situations, every foot of stopping distance can be the difference between avoiding an accident and being involved in a collision, making this defect particularly alarming.
In essence, the EBB system replaces traditional vacuum-operated brake boosters with an electric motor to provide braking assist. These systems are designed to offer more precise stopping control, and are also crucial in electric vehicles where a vacuum source is not available. When this precision and assist are lost, the vehicle’s braking performance is severely degraded.
3. **The Technical Nuance: Voltage Fluctuations Leading to EBB Malfunction**To fully grasp the nature of this recall, it’s essential to understand the technical root cause behind the electronic brake booster’s malfunction. Ford’s investigation, supported by the National Highway Traffic Safety Administration (NHTSA), pinpointed a specific electrical sensitivity within the EBB module itself.
The problem stems from the EBB motor’s susceptibility to voltage disturbances. The module is designed with an over-current monitoring threshold. However, if a voltage drop occurs within the system and then quickly recovers, this can cause a momentary current surge that exceeds the unit’s programmed limits. This surge is the critical factor that triggers the defect.
When this current spike exceeds the threshold, the EBB module responds by shutting down the EBB motor. This shutdown is what directly leads to the loss of power brake assist that drivers may experience. It’s a protective mechanism gone awry, where an electrical fluctuation intended to be minor can cause a major safety system to cease functioning correctly.
According to the recall report, small changes in EBB voltage are considered to be normal occurrences within the vehicle’s electrical system, though they happen infrequently. The issue, therefore, lies not in the presence of these voltage variations, but in the EBB module’s incorrect and problematic response to them, leading to its critical shutdown and the subsequent loss of vital braking assistance.
When the EBB motor shuts down, drivers may experience several warning signs. These can include the illumination of warning lights and messages within the instrument cluster, as well as audible alerts. Critically, there will be a noticeable and concerning change in the brake pedal feel, requiring significantly more effort to apply the brakes with any effectiveness.
4. **The Paramount Safety Risk: Increased Stopping Distances and Crash Potential**The most immediate and severe consequence of the electronic power brake assist defect is the significant increase in stopping distances. When the EBB module malfunctions and power brake assist is lost, a driver attempting to stop their vehicle will find that it takes much longer and travels a greater distance before coming to a halt.
This extended stopping distance dramatically elevates the risk of a crash. In everyday driving scenarios, particularly in unexpected situations like sudden stops in traffic, or when a pedestrian or animal unexpectedly enters the road, the ability to stop quickly is absolutely crucial. A vehicle that requires more distance to stop compromises this fundamental safety capability.
Ford, as of July 11, 2025, was aware of 37 warranty claims directly related to a loss of brake assist. Furthermore, the company reported one alleged low-speed crash that may be connected to this issue. While it is reassuring that no injuries or fires have been reported in connection with this specific recall, the potential for harm remains very real and is the primary driver behind this urgent safety action.
For consumers, understanding this risk is paramount. Even a slight increase in stopping distance can be catastrophic, particularly at higher speeds or in adverse weather conditions. The defect essentially strips the driver of a vital layer of braking control and responsiveness, placing them and others on the road in a more perilous situation. It underscores why prompt action on this recall is not just recommended, but critical for personal safety.
5. **Interplay with Modern Tech: ADAS Features and Elevated Risk**Adding another layer of concern to this recall is the specific mention that the electronic brake booster (EBB) module may malfunction, particularly when advanced driver assistance system (ADAS) features are in use. This interaction highlights a growing complexity in modern vehicle safety systems and their potential vulnerabilities.
ADAS features encompass a wide array of technologies designed to enhance driver safety and reduce the likelihood of collisions, such as adaptive cruise control, automatic emergency braking, and lane-keeping assist. Many of these systems rely heavily on the vehicle’s braking capabilities to function correctly and provide their intended safety benefits.
When the EBB module malfunctions while ADAS features are active, it creates a particularly troubling scenario. The very systems designed to assist and protect drivers may become compromised, potentially leading to unexpected vehicle behavior or a failure to brake as anticipated by the ADAS system itself. This concern is especially alarming when modern safety features are engaged, as it could further elevate crash risks.
The Detroit automaker explicitly stated that the problem stems from a potential failure in the Electronic Brake Booster (EBB) module, which may occur while driving or when using the vehicle’s Advanced Driver Assistance System (ADAS). This emphasizes that even with the most sophisticated safety technologies activated, a fundamental mechanical or electrical defect can still undermine overall vehicle safety, necessitating immediate attention.
6. **Ford’s Proactive Discovery and Rigorous Investigation**Ford’s initiation of this recall follows a thorough internal investigation process, demonstrating a commitment to identifying and addressing potential safety concerns. The journey to this recall began on May 14, 2025, when the Ford Expedition/Navigator Rapid Response Team first identified a vehicle exhibiting a loss of power brake assist.
This initial incident involved a management lease program vehicle, which provides lease deals to Ford employees. The vehicle not only experienced the brake assist loss but also stored a specific diagnostic trouble code (DTC), which served as a crucial piece of evidence in tracing the root cause of the problem. This immediate identification within Ford’s own fleet allowed for quick action.
Following this initial discovery, Ford utilized its connected vehicle database extensively from May through June. This allowed investigators to identify other models that had stored similar diagnostic trouble codes believed to be linked to the brake issue. This data-driven approach enabled Ford to understand the potential scope of the problem much more efficiently.
Further broadening their investigation, Ford reviewed vehicle data logs and conducted meetings with drivers who had reported experiencing a sudden loss of power brake assist. These drivers shared experiences of excessive pedal travel or longer stopping distances, providing invaluable real-world feedback to help determine the full scope and nature of the defect.
This rigorous investigative approach led Ford investigators to conclude that the electronic brake booster (EBB) module could indeed malfunction, whether during routine driving or specifically when a driver was using an advanced driver assist system feature. The Ford’s Field Review Committee then approved the recall on July 18, solidifying the company’s decision to address this critical safety concern proactively and systematically.
Navigating a recall can be a complex process for vehicle owners, but Ford has outlined clear pathways for rectifying the electronic power brake assist defect. Our focus in this section shifts to understanding these solutions, the logistics of owner notification, and the broader context of this recall within Ford’s extensive activities this year, along with its implications for both dealerships and consumer confidence.
Car Model Information: 2019 Ford Expedition Max Limited
Name: Ford Expedition
Manufacturer: Ford Motor Company
Production: 1996–present
ModelYears: 1997–present
Class: Full-size car,Sport utility vehicle
Related: Lincoln Navigator
BodyStyle: Sport utility vehicle
Layout: Front-engine, rear-wheel-drive layout,Front-engine, four-wheel-drive layout
Chassis: Body-on-frame
Predecessor: Ford Bronco,Ford Excursion
Categories: 2000s cars, 2010s cars, 2020s cars, All-wheel-drive vehicles, All Wikipedia articles written in American English
Summary: The Ford Expedition is a full-size SUV produced by Ford Motor Company since the 1997 model year. The successor to the Ford Bronco, the Expedition shifted its form factor from an off-road oriented vehicle to a truck-based station wagon. Initially competing against the Chevrolet Tahoe, the Expedition also competes against the Toyota Sequoia, Nissan Armada, and the Jeep Wagoneer.
First used for a 1992 F-150 concept vehicle, Ford first marketed the Expedition nameplate for 1995 on a trim level package for the two-door Ford Explorer Sport. As with its Bronco predecessor, the Expedition is heavily derives its chassis from the Ford F-150, differing primarily in suspension configuration. All five generations of the Expedition have served as the basis of the Lincoln Navigator–the first full-size luxury SUV. The model line is produced in two wheelbases (an extended-wheelbase variant introduced was introduced for 2007, largely replacing the Ford Excursion), with seating for up to eight passengers.
Ford currently assembles the Expedition at its Kentucky Truck Assembly facility (Louisville, Kentucky) alongside the Lincoln Navigator and Super Duty trucks. Prior to 2009, the model line was assembled by the Michigan Assembly Plant (Wayne, Michigan).
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7. **Ford’s Proposed Solutions: Over-the-Air (OTA) and Dealership Service**Ford is providing two primary avenues for vehicle owners to address the critical electronic brake booster (EBB) module defect, ensuring accessibility and convenience for all affected individuals. The good news is that both solutions will be provided entirely free of charge to vehicle owners. This commitment underlines Ford’s dedication to resolving the issue without imposing additional financial burdens on its customers.
The first and arguably most convenient solution is an over-the-air (OTA) software update. This cutting-edge approach allows vehicles with the necessary connectivity to receive the critical software patch remotely, much like how a smartphone updates its operating system. Ford explicitly states that “Drivers can do an over-the-air software update,” which is designed to “correct the EBB module’s response to voltage changes.” The updated EBB module software is expected to be available by the end of August, ensuring that it remains operational even if minor voltage variations occur.
For those who prefer a traditional service experience or whose vehicles may not be equipped for OTA updates, Ford offers an equally straightforward alternative. Owners can “schedule a service appointment at a dealership to have the update performed free of charge.” This option provides peace of mind, knowing that certified technicians will install the necessary software update. The “free software update for the EBB module” is available through “Ford and Lincoln dealers,” streamlining the process for every affected customer.
This dual approach underscores Ford’s recognition of varying owner preferences and technological capabilities across its diverse customer base. Whether opting for the seamless remote update or the hands-on dealership service, the fundamental goal remains the same: to correct the EBB module’s problematic response to voltage fluctuations, thereby restoring full power brake assist and ensuring optimal vehicle safety. The provision of these remedies at no cost further reinforces the consumer-centric approach to this recall.
8. **Owner Notification and Timeline**Prompt and clear communication is paramount in any safety recall, and Ford has laid out a specific timeline for notifying affected vehicle owners. Understanding when and how you will be informed is crucial for taking timely action to address the power brake assist defect. This systematic notification process is designed to ensure that every potentially impacted owner receives the vital information they need.
According to official statements, “Owner notification letters are expected to be mailed on Aug. 25, providing further instructions on how to proceed.” Further details clarify that these “owner notification letters [will be] mailed between August 25 and 29.” This window provides a clear expectation for when affected individuals should anticipate receiving their official recall correspondence. These letters will contain all necessary instructions regarding the free software update, whether via OTA or at a dealership.
Beyond the formal letters, consumers have additional resources available to verify if their vehicle is part of this recall and to obtain more information. For direct inquiries, “consumers can contact Ford customer service at 1-866-436-7332.” Moreover, details regarding the recall are publicly accessible “on the NHTSA website under ID number 25V488000.” Crucially, owners are also “urged to check their vehicle identification number (VIN) on the NHTSA or Ford recall websites to see if they’re affected.” This proactive step allows owners to confirm their vehicle’s status even before receiving a letter.
Taking immediate action upon receiving notification or confirming eligibility through a VIN check is highly recommended. The prompt application of the software update is critical for ensuring the safe operation of your vehicle and mitigating the increased risks associated with compromised braking performance. Ford’s clear communication strategy aims to empower owners to make informed decisions and act swiftly for their safety and the safety of others on the road.
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9. **The Role of the Component Supplier: Bosch**In the complex ecosystem of modern automotive manufacturing, vehicles are assembled from thousands of components, many of which are supplied by specialized external partners. In the case of this particular recall concerning the electronic brake booster (EBB) module, Ford has identified the specific Tier 1 supplier responsible for the component. This transparency provides important context for understanding the supply chain dynamics behind critical safety systems.
The problematic EBB units, which are susceptible to voltage disturbances leading to a loss of power brake assist, were sourced from “Tier 1 supplier Bosch.” Bosch is a globally recognized engineering and technology company, well-known for its automotive components and systems. Identifying the supplier highlights that even highly reputable manufacturers can encounter unexpected issues within specific batches or designs of components.
The core of the defect, as previously detailed, “stems from the EBB motor’s sensitivity to voltage disturbances.” This means that while the overall system design by Ford incorporates the EBB module, the specific vulnerability lies within the module itself, as manufactured by Bosch. The malfunction occurs when “a voltage drop occurs and then recovers, a current surge may exceed the system’s limits, shutting down the motor.” This technical detail underscores the intricate electronic precision required for such critical safety components.
While Ford is ultimately responsible for the recall and the safety of its vehicles, the involvement of a Tier 1 supplier like Bosch points to the collaborative nature of modern automotive production. The recall process involves not only the automaker but also its suppliers in identifying and rectifying defects. Ford’s forthcoming software update for the EBB module, therefore, represents a coordinated effort to ensure the component operates as intended, regardless of minor voltage fluctuations within the vehicle’s electrical system.
10. **Ford’s Unprecedented Recall Activity in 2025**This latest brake assist recall, while significant, is not an isolated incident within Ford’s recent operational history. The year 2025 has seen an exceptional volume of recall activity from the automaker, placing it under considerable scrutiny. Examining this broader context helps to understand the company’s current approach to vehicle quality and safety.
Indeed, Ford has experienced an “unprecedented” number of safety recalls this year. “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.” This staggering figure highlights a period of intense focus on identifying and rectifying potential defects across its vast fleet. These numerous recalls collectively “potentially extend to over 6.4 million vehicles,” underscoring the widespread impact of these safety actions.
Ford attributes this high volume not to a decline in quality, but rather to a proactive and enhanced approach to safety. The company “attributes the high number to ongoing audits and follow-ups on previous software-based recalls, reflecting its effort to proactively address safety issues.” Furthermore, in a commitment to bolstering vehicle quality, “Ford has more than doubled its team of safety experts to improve vehicle quality.” This suggests an internal drive to catch and resolve issues more comprehensively and earlier than before.
Beyond the EBB module issue, Ford has faced other significant recalls this year. “Also in July, Ford recalled about 694,000 vehicles due to a risk of fuel injector cracks that could cause fuel leaks and engine fires.” This particular recall affected certain 2021–2024 Bronco Sport and 2020–2022 Escape models. Earlier in the year, “as of the end of June, the automaker had announced 88 safety recalls, including a recent one involving 850,000 trucks and SUVs over a potential fuel-pump failure.” This pattern of recalls across various systems and models illustrates the breadth of Ford’s ongoing safety improvements and rigorous internal reviews.
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11. **Broader Implications for Dealerships**When a major automaker like Ford announces a substantial recall, the ripple effects extend far beyond the manufacturing floor and directly impact its extensive network of dealerships. For Ford and Lincoln dealers, this EBB module recall presents both challenges and opportunities, profoundly influencing their day-to-day operations and customer relationships. Dealerships serve as the front line for implementing recall remedies and managing customer concerns.
Dealers are advised to “monitor recall activity closely as it directly impacts customer trust, dealership service volume, and parts demand.” High-profile safety actions invariably lead to an increase in service appointments as owners seek to have the necessary updates performed. This surge in volume requires robust planning for scheduling, staffing, and managing workshop capacity to efficiently handle the influx of affected vehicles.
Furthermore, recalls can have a nuanced effect on market perceptions and vehicle valuations. “High-profile recalls like this one can lead to increased service appointments, affect used vehicle resale values, and influence how consumers view the reliability of new models.” Dealers must be prepared to address customer questions about vehicle reliability and potential impacts on resale value, leveraging transparent communication to maintain confidence. It is also “crucial for dealers to check VINs and ensure accuracy in recall notifications” to avoid unnecessary service or missed opportunities to help a customer.
Ultimately, these situations provide a critical opportunity for dealerships to reinforce customer loyalty. “Offering fast, transparent support during a recall is critical for retaining customer loyalty and protecting the brand image at the retail level.” By providing seamless, free, and efficient service, “service departments should prepare for increased customer visits and leverage this opportunity to reinforce service retention strategies and educate customers on ADAS reliability.” A well-managed recall can transform a potential negative into a chance to showcase exceptional customer care and reinforce trust.
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12. **Impact on Consumer Confidence and Brand Image**Beyond the technical fixes and operational adjustments, Ford’s recall activity, particularly high-profile cases like the electronic power brake assist defect, inevitably influences the public’s perception of the brand. Consumer confidence is a fragile commodity, built over years of consistent quality and reliability, and it can be tested significantly by safety concerns. This section explores how current recalls may shape Ford’s image in the eyes of its customers.
The consistent stream of recalls, even if driven by proactive measures, naturally raises questions about vehicle reliability among consumers. The fact that high-profile recalls “influence how consumers view the reliability of new models” is undeniable. Every recall notice, particularly one concerning a fundamental safety system like brakes, prompts owners and prospective buyers to consider the dependability of Ford vehicles. Maintaining “customer trust” becomes a paramount challenge in such an environment.
While Ford has stated it is “not currently facing legal action over the recall,” the landscape of consumer advocacy and litigation means that organizations like Top Class Actions “follows recalls closely as they sometimes lead to class action lawsuits.” It’s also worth noting that “Ford has recently initiated several recalls and faced multiple class action lawsuits involving issues with its vehicles’ oil pumps, rear subframe assemblies, 10-speed transmissions, seat belts, engines and battery monitor sensors.” This history, whether related or not, can collectively contribute to a broader narrative about the brand’s quality control.
Ford’s commitment to addressing these issues, evidenced by proactive audits and increased safety expert teams, is crucial for mitigating negative impacts on its brand image. By transparently communicating the problem, offering clear solutions, and ensuring free and efficient remedies, Ford can work to rebuild and reinforce the confidence of its customer base. The long-term health of the brand hinges on not just fixing the immediate defects, but also on how effectively it communicates its dedication to safety and quality to the driving public.
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Ford’s latest recall, addressing the critical electronic power brake assist defect in a substantial number of its 2025 F-150, Ranger, Expedition, Bronco, and Lincoln Navigator models, underscores the complexities of modern automotive engineering. While the immediate focus is on the crucial over-the-air software updates and dealership service options, this situation also highlights the broader commitment required from automakers to uphold safety standards. For vehicle owners, acting quickly by checking your VIN and scheduling the free software update is not merely a recommendation but a vital step to ensure the safety of yourself and your loved ones on the road. Ford’s proactive investigation and robust solutions demonstrate a serious approach to safety, reinforcing the principle that informed and decisive consumer action remains the best defense against unforeseen automotive risks.
