Urgent Alert for Ford Super Duty Owners: Critical Brake Recall Explained, What You Need to Know

Ford, a prominent name in the automotive industry, has recently issued a significant safety recall that demands the immediate attention of its Super Duty truck owners. This particular campaign, affecting certain F-250, F-350, F-450, and F-550 models, addresses a critical issue that can lead to a sudden and unexpected loss of braking ability. Given the severe potential consequences, Ford has taken the serious step of issuing a “Do Not Drive” warning to impacted owners, underscoring the urgency and the paramount importance of vehicle safety.

Understanding the intricacies of this recall is vital for affected individuals. It is not merely a minor defect but a fundamental safety concern tied to the brake pedal assembly. Our objective is to provide a comprehensive, factual, and actionable overview of this situation, ensuring that every affected Super Duty owner has the clear and concise information needed to respond effectively. We will delve into the technical specifics of the problem, outline the precise models and production dates involved, detail how this issue came to light, and most importantly, guide owners through the steps Ford is taking to rectify it at no cost.

This article is designed to empower you with verified facts and expert analysis, prioritizing your safety and financial well-being. We aim to cut through any confusion and present a straightforward path forward, explaining the potential risks and providing clear guidance on what actions consumers should take. Let’s break down the critical aspects of this recall so you can navigate this situation with confidence and ensure the safety of yourself and those around you.

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1. The Urgent Safety Alert and ‘Do Not Drive’ Warning

Ford has issued a safety recall for 2,345 Super Duty trucks, spanning models from F-250 through F-550, due to a severe mechanical fault. This issue carries the potential for a sudden and unexpected loss of braking ability, a hazard serious enough to warrant a “Do Not Drive” warning for those impacted owners. This immediate directive highlights the critical nature of the defect and Ford’s commitment to preventing potential accidents or injuries before they occur.

The “Do Not Drive” warning is not a measure taken lightly by automakers; it is reserved for circumstances where continuing to operate a vehicle poses an unacceptable risk. It underscores the severity of the brake issue, where a complete loss of braking function while driving could drastically increase the risk of a crash. Ford’s clear instruction to owners to avoid driving their vehicles unless the presence of the brake booster pushrod retaining spring is verified is a direct response to this high-risk scenario.

Owners receiving this warning must prioritize their safety and heed Ford’s advice. The company is actively working to facilitate the inspection and repair process, ensuring that affected trucks are made safe without delay. This proactive and assertive stance, while inconvenient for owners, is a crucial step in upholding safety standards and mitigating the inherent dangers associated with brake system failures on the road.

Car Model Information: 2023 Honda Accord LX
Name: Ford Super Duty,(F-250/F-350/F-450/F-550/F-600)
Caption: 2020 Ford F-250
Manufacturer: Ford Motor Company
Production: January 5, 1998–present
ModelYears: 1999–present
Class: pickup truck
Layout: Front-engine, rear-wheel-drive layout
Predecessor: Ford F-Series (ninth generation)
Categories: 2000s cars, 2010s cars, All-wheel-drive vehicles, All articles with bare URLs for citations, Articles with bare URLs for citations from August 2024
Summary: The Ford Super Duty (also known as the Ford F-Series Super Duty) is a series of heavy-duty pickup trucks produced by the Ford Motor Company since the 1999 model year. Slotted above the consumer-oriented Ford F-150, the Super Duty trucks are an expansion of the Ford F-Series range, from F-250 to the F-600. The F-250 through F-450 are offered as pickup trucks, while the F-350 through F-600 are offered as chassis cabs. Rather than adapting the lighter-duty F-150 truck for heavier use, Super Duty trucks have been designed as a dedicated variant of the Ford F-Series. The heavier-duty chassis components allow for heavier payloads and towing capabilities. With a GVWR over 8,500 lb (3,900 kg), Super Duty pickups are Class 2 and 3 trucks, while chassis-cab trucks are offered in Classes 3, 4, 5, and 6. The model line also offers Ford Power Stroke V8 diesel engines as an option. Ford also offers a medium-duty version of the F-Series (F-650 and F-750), which is sometimes branded as the Super Duty, but is another chassis variant. The Super Duty pickup truck also served as the basis for the Ford Excursion full-sized SUV. The Super Duty trucks and chassis-cabs are assembled at the Kentucky Truck Plant in Louisville, Kentucky, and at Ohio Assembly in Avon Lake, Ohio. Prior to 2016, medium-duty trucks were assembled in Mexico under the Blue Diamond Truck joint venture with Navistar International.

Get more information about: Ford Super Duty

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2. Specifics of the Brake System Failure: The Missing Retaining Spring

The root cause of this alarming recall lies within the brake pedal assembly of the affected Super Duty trucks. As detailed in the recall report published by the National Highway Traffic Safety Administration (NHTSA), the brake pedal assembly on these vehicles “may have been improperly assembled without a retaining spring.” This small, yet critically important, spring is designed to secure the brake booster pushrod to the brake pedal, forming a vital connection within the braking system.

Without this retaining spring, the two crucial parts—the brake booster pushrod and the brake pedal—can detach from each other. Such a detachment would compromise the integrity of the braking system. If this separation occurs, particularly while the vehicle is in motion, it can result in a significant “loss of braking function while driving, increasing the risk of a crash,” as explicitly stated in the NHTSA report. The implications of this mechanical fault are dire, transforming a routine drive into a perilous journey.

The brake booster plays a crucial role in reducing the effort required by the driver to apply the brakes, making the vehicle easier and safer to stop. Losing the connection to this booster means a driver could suddenly find their brake pedal unresponsive or ineffective, leading to a terrifying and dangerous situation. The absence of this single, inexpensive component creates a cascade of potential failures, directly impacting vehicle control and occupant safety.

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3. Affected Vehicles and Production Timeline

This recall specifically targets a limited, but significant, population of Ford Super Duty trucks. A total of 2,345 units are involved, encompassing the F-250, F-350, F-450, and F-550 models. Ford has meticulously identified the breakdown of affected units by model: 1,304 F-250 units, 807 F-350 units, 132 F-450 units, and 102 F-550 units. The F-250 is the most heavily impacted model in this particular campaign.

All trucks covered by this recall were manufactured at Ford’s Kentucky Truck Plant in Louisville. The critical production window during which the assembly error occurred spans from March 19 to May 4, 2025. This precise timeframe is crucial for owners to verify if their vehicle falls within the affected batch. Owners of Super Duty trucks manufactured within these dates should be particularly vigilant and proactive in checking their vehicle’s status.

Identifying the specific manufacturing plant and dates allows Ford to pinpoint the exact circumstances that led to the defect and helps owners quickly determine their potential risk. It’s important for owners to remember that while their truck might fall within this timeframe, not all vehicles produced during this period are necessarily affected. Verification through official channels, such as Ford’s recall website or the NHTSA database, using their Vehicle Identification Number (VIN), remains the most reliable method.

Car Model Information: 2016 Ford F-250 XL
Name: Ford F-Series
Caption: 2022 Ford F-150 Lariat Luxury
Manufacturer: Ford Motor Company
Aka: Ford Lobo (Mexico, 1992–present)
Production: 1948–present
Class: Pickup truck#Full-size pickup truck
Layout: Front-engine, rear-wheel-drive layout,rear-wheel drive
Predecessor: 1941 Ford
Categories: All-wheel-drive vehicles, All Wikipedia articles written in American English, All articles that may contain original research, All articles with unsourced statements, Articles that may contain original research from September 2020
Summary: The Ford F-Series is a series of light-duty trucks marketed and manufactured by the Ford Motor Company since model year 1948 as a range of full-sized pickup trucks — positioned between Ford’s Ranger and Super Duty pickup trucks. Alongside the F-150 (introduced in 1975), the F-Series also includes the Super Duty series (introduced in 1999), which includes the heavier-duty F-250 through F-450 pickups, F-450/F-550 chassis cabs, and F-600/F-650/F-750 Class 6–8 commercial trucks.

Get more information about: Ford F-Series

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4. How the Problem Was Discovered: From Plant Report to Dealer Flags

The discovery of this serious braking issue followed a structured process involving both internal reporting and pre-delivery inspections. Ford’s Critical Concern Review Group (CCRG) first became aware of the problem on May 22, 2025, after it was reported by the manufacturing team at the Kentucky Truck Plant. This initial report signaled an internal recognition of a potential quality control lapse during the assembly process.

Further confirmation emerged from the field through pre-delivery inspection reports. On May 5, a dealer technician flagged a 2025 F-350 Super Duty that exhibited “no braking force when driving the trucks at parking lot speeds.” The technician observed that the brake pedal was swinging freely, subsequently tracing the issue to a disconnected brake booster pushrod from the brake pedal assembly. This real-world observation validated the internal plant report.

The severity of the issue was reinforced when another technician reported the identical problem during a pre-delivery inspection of a second 2025 model year F-350 on June 3. These independent reports from dealer technicians during critical pre-delivery checks demonstrated that the manufacturing defect was not an isolated incident, prompting a deeper investigation by Ford into the root cause and scope of the problem.

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5. Root Cause Analysis: Human Error and System Failure

Ford’s investigation into the cause of the missing retaining springs revealed a dual-layered issue, pointing to both human factors and system deficiencies. The company informed safety regulators that it determined the critical retaining spring installation on the two initially flagged trucks was supposed to have been performed by a new operator. This operator was undergoing training during the suspect production period when the affected vehicles were assembled.

This indicates a lapse in the training or supervision of new personnel on a critical assembly step. The installation of such a small but vital component might have been overlooked or incorrectly performed by an operator still learning the ropes of the manufacturing process. This highlights the importance of rigorous training protocols and stringent oversight, particularly for tasks directly impacting vehicle safety.

Compounding this human error, the CCRG also identified a significant system failure. The camera system designed to detect errors in the manufacturing process for this specific part was either completely non-operational or failed to provide sufficient clarity. Consequently, the system could not reliably determine whether the operator had, in fact, installed the retaining spring on the affected trucks. This dual failure—human error combined with a critical quality control system malfunction—allowed the defect to bypass detection and reach completed vehicles.

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6. Immediate Actions for Owners: Inspection, Repair, and Support

Ford has moved swiftly to address this recall, ensuring that owners are notified and their vehicles are made safe without undue delay. Dealers were first informed of this braking recall on June 13, and owner notification letters began dispatching as early as Wednesday, June 18, with the process expected to conclude by June 23. This rapid communication timeline aims to get critical information into the hands of affected owners as quickly as possible.

Upon receiving notification, owners will be advised not to drive their trucks unless the presence of that crucial brake booster pushrod retaining spring is verified. Ford is instructing customers to “work with their Ford or Lincoln dealer to have the brake pedal assembly inspected and repaired, as necessary,” all at no charge to the owner. This ensures that the financial burden of a safety-related defect does not fall upon the consumer, a standard practice for recall remedies.

To further facilitate the repair process, Ford has authorized dealers to proactively contact owners in the recall population and arrange for a mobile repair service for inspection and assembly repair, or to tow vehicles to the dealership if necessary. Should a vehicle require towing and dealership service, Ford also authorizes a rental car for the owner and ensures the vehicle is redelivered after the recall completion. Owners can also verify their vehicle’s status by searching the NHTSA recall website (recall number 25V-401) or Ford’s recall website (recall number 25C26) using their VIN.

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7. Broader Context: Ford’s Prolific Recall History in 2025

This particular Super Duty campaign marks Ford’s 77th recall this year, an astonishing figure that positions the automaker as the leader in vehicle recalls. It’s a statistic that certainly catches the eye, emphasizing a period of intense activity for the Blue Oval. For consumers, such a high number naturally raises questions about overall vehicle quality and manufacturing consistency.

It’s worth bearing in mind that we’re only about halfway through the year 2025 so far. An additional recall involving the Mustang Mach-E brings Ford’s total to 78, accounting for approximately 39% of all NHTSA-listed recalls among manufacturers during this period. This sheer volume indicates a comprehensive effort to address potential issues across their product lines, though the frequency is notable.

When we look at the landscape of other automakers, Ford’s lead becomes even more pronounced. Behind them, RV manufacturer Forest River Inc. registers the next greatest number of recalls, at 18. As far as conventional automotive manufacturers are concerned, Volkswagen and FCA (Chrysler/Stellantis) each have 15 recalls, placing them third and fourth respectively. Mercedes-Benz rounds out the top five with 13 recalls, while General Motors and Honda both report 12, highlighting Ford’s significant lead in this area.

It’s also important to note the nature of these widespread issues. While many recent recalls often pertain to software problems, this Super Duty brake issue is a critical mechanical fault. This distinction underscores the severity of the current brake recall, reminding us that not all recalls are created equal in terms of their immediate safety implications.

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8. The Cumulative Impact of Super Duty Recalls

While this specific recall campaign affects a relatively limited number of vehicles, precisely 2,345 Super Duty trucks, its significance deepens when considered within a broader pattern. This is not an isolated incident; it stands among at least a dozen other recalls that have impacted the fifth-generation Super Duty since its introduction in 2023. Such a recurring pattern indicates a systemic challenge.

To illustrate the scale of some of these issues, one of the most recent prior campaigns involved the Super Duty’s inclusion in a massive 1.1-million-strong rearview camera recall. This widespread issue impacted several Ford models and numerous other camera-related recalls, suggesting that quality concerns are not confined to a single component or model line, but rather represent a more pervasive situation.

Collectively, these repeated campaigns are indicative of a broader quality issue within certain Ford manufacturing processes or design phases. For owners, this can translate into frequent dealership visits, inconvenience, and a potential erosion of confidence in their vehicles. It suggests a need for a deeper dive into quality control from the manufacturer’s side.

The overall impact extends beyond individual incidents. Between January 1 and June 20, Ford’s recall campaigns have affected as many as 4,077,623 vehicles. It’s important to remember that some vehicles may be included in multiple recalls, and would therefore be counted more than once in this total figure, but the sheer number underscores the scope of their challenges.

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9. Ford Management’s Acknowledgment and Response to Quality Concerns

The extensive nature of these recalls has not gone unnoticed at the highest levels of Ford’s corporate structure. Indeed, the company brass are acutely aware of these significant problems. Last year, CEO Jim Farley openly acknowledged Ford’s build quality issues when speaking to investors, demonstrating an understanding of the gravity of the situation.

In his candid remarks, Farley shared a personal reflection on the matter, stating, “I think we all have regrets and that’s a big one for me.” This quote, reported by Axios, highlights the company’s internal recognition that addressing these quality challenges is a top priority and a source of considerable concern for leadership.

In a decisive move to strengthen its commitment to quality, Ford announced in December 2024 the appointment of a new head of quality. This role was taken over from Jim Baumbick, who formally transitioned out of that position in 2025 to become VP of advanced product (EV) development and cycle planning. Such a change in leadership at a critical function signals a strategic effort to refocus and elevate quality control across the organization.

Moreover, the company is actively leveraging technological advancements in its manufacturing processes. Ford is further using artificial intelligence (AI) in its factories specifically to enhance quality control measures. This integration of AI aims to improve detection capabilities and prevent manufacturing errors before vehicles reach consumers, representing a forward-looking approach to addressing systemic issues.

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10. The Essential Role and Effectiveness of the Recall System.

Amidst the concerns raised by a high volume of recalls, it is crucial to recognize the inherent value and effectiveness of the vehicle recall system itself. In this particular Super Duty instance, Ford appears to have caught the brake spring issue relatively early in its lifecycle. This swift detection is undoubtedly great news for consumers, as it demonstrates the recall system functioning as intended.

The fundamental purpose of these systems is to identify and address manufacturing defects or design flaws ideally before they lead to injuries or fatalities. When a company, like Ford in this case, acts quickly and decisively, it underscores the critical importance of these regulatory frameworks. They serve as a vital safety net, protecting the public from potentially catastrophic failures.

From a consumer perspective, these ongoing campaigns should be viewed as an encouragement for continued vigilance and commitment to quality. The hope remains that such proactive measures will motivate manufacturers to constantly refine their production and inspection processes, leading to fewer recalls in the future. For the sake of safety on our roads, this continuous improvement is paramount, fostering greater trust between automakers and their customers.

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11. Owner Community Feedback: Initial Reactions and Inspections

Beyond the official notices and technical details, the real-world impact and immediate reactions of the owner community provide valuable insights into the recall’s significance. Discussions on online forums reveal a mix of apprehension, diligent checks, and eventual relief among those whose vehicles fall within the affected production timeframe. These firsthand accounts offer a tangible sense of the recall’s practical implications.

One owner, identified as ‘FordCornersTremor,’ whose new Black F350 Tremor was built within the identified timeframe, expressed initial unhappiness upon learning of the recall. After contacting their dealer, located 60 miles away, they received confirmation that their VIN was in the system, and their truck had, fortunately, avoided the recall. The owner recounted a recent camping trip on a very steep forest service road, highlighting the terrifying prospect of ‘going to hit the brake pedal a little and it goes to the floor & disappear. No brakes on the truck which would also take out the trailer brakes.’ The profound relief at not being impacted underscores the severe safety concerns and the immediate psychological toll such alerts can take.

Similarly, ‘Bowdiddly,’ an F250 7.3 Liter Tremor owner, confirmed their truck was also built during the identified production period. Taking a proactive approach, this owner personally inspected the linkage underneath the dashboard that morning and found that the described part was not missing. This self-verification provided considerable peace of mind, indicating that their truck would not require dealer intervention for this specific issue, saving them a trip to the service center.

Another forum participant, ‘Avslash,’ a 2025 Platinum Tremor 6.7 owner whose vehicle was built in April, also shared a direct visual confirmation. Despite their vehicle being within the potentially affected period, their inspection clearly showed ‘a nice bright yellow spring and the retaining clip’ in place, suggesting their vehicle was correctly assembled. These immediate checks by owners, verifying the presence of the critical component, demonstrate both a responsible approach to vehicle safety and a strong desire for reassurance.

The collective experiences from the owner community reveal a blend of initial shock, followed by diligent investigation and a sense of relief for those whose vehicles were deemed safe. For many, the initial ‘Do Not Drive’ warning quickly led to independent inspections or prompt dealer verification. This proactive engagement from owners is a testament to the importance of transparent recall communication and the vital role of these communities in sharing information and providing support during such critical alerts.

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12. Actionable Advice and Resources for Owners

For all owners of potentially affected Ford Super Duty trucks, the path forward remains unequivocally clear: prioritize safety by adhering to Ford’s instructions. The solution to this critical defect is straightforward and designed to minimize disruption and cost to the consumer. Ford dealers will inspect the impacted trucks and repair the brake pedal assembly if needed, all at no charge, as mandated by law for safety recalls.

It is paramount that owners adhere to Ford’s urgent advice not to drive any affected vehicles until the presence of that crucial brake booster pushrod retaining spring is definitively verified. This ‘Do Not Drive’ directive is not issued lightly; it underscores the severe risk of continuing to operate a vehicle with this potential defect, making immediate action a critical safety measure.

Owners seeking comprehensive information and a means to verify their specific vehicle’s status have reliable official channels at their disposal. They can search the NHTSA recall website using recall number 25V-401 for detailed reports. Alternatively, by entering their Vehicle Identification Number (VIN) on Ford’s official recall website, referencing recall number 25C26, they can receive accurate and up-to-date information pertaining to their individual truck.

Further supporting documents, such as detailed technical bulletins and owner notices available through PDF links from Ford and NHTSA, provide additional specific instructions and visual aids. These resources are invaluable for those seeking a deeper understanding of the inspection and repair process, ensuring every owner has the necessary tools to comprehend and act effectively on this critical safety recall.

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The recent Ford Super Duty recall, while unsettling for affected owners, serves as a powerful reminder of the automotive industry’s continuous commitment to safety and the robust mechanisms in place to protect consumers. From the diligent eyes of plant workers and dealer technicians to the responsive actions of corporate leadership and the engagement of the owner community, every layer plays a vital role in ensuring that vehicles on our roads meet the highest safety standards. As Ford continues its efforts to enhance quality control, leveraging both human expertise and advanced technology, the hope remains that such swift, comprehensive actions will increasingly prevent issues before they arise, keeping every journey safe and secure. For now, vigilance and prompt action are the keys to navigating this and any future recall, reaffirming the trust between manufacturer and driver.