Thousands of Ford vehicles are being recalled due to an issue that disables the power brake system

Ford Recalls Over 6.4 Million Vehicles Due to Electronic Brake Booster Issue

Ford Motor Company has announced a recall of over 6.4 million vehicles, making it the highest number of recalls for any automaker in a single year, according to data from the National Highway Traffic Safety Administration (NHTSA). The recall, which affects the 2025 F-150, Ranger, Expedition, Bronco, and Lincoln Navigator models built between November 2023 and June 2025, is due to a potential issue with the Electronic Brake Booster (EBB) system.

The problem was discovered by Ford on May 14 and was identified on a management lease program vehicle. Investigators met with drivers who experienced a sudden loss of power brake assist, excessive pedal travel, or longer stopping distances to determine the scope of the problem. 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 related to these incidents.

The EBB in the recalled vehicles replaces a traditional vacuum-operated brake booster with an electric motor to provide braking assist. The units were sourced from Tier 1 supplier Bosch. Small changes in EBB voltage are considered to be normal but happen infrequently. However, the automaker has found that these changes can lead to a momentary current spike exceeding the unit's over-current monitoring threshold, causing the EBB motor to shut down and result in a loss of power brake assist.

To correct this issue, Ford will release a revised EBB module software by the end of the month. This software update will correct the unit's response to voltage changes and ensure that it remains operational if any variations occur. Owner notification letters are expected to be mailed on Aug. 25, and customers have the option to schedule a service appointment at a dealer to have the update performed, free of charge.

It is worth noting that this is not the first time Ford has faced issues with its EBB system. In 2023, a leading Tier-1 supplier for brake systems experienced quality issues, although the name of the specific supplier is not explicitly mentioned in the search results. Another Tier-1 supplier known for brake system components for international commercial vehicles is DJJ Precision Engineering, based in Newport, South Wales, UK.

Despite the recall, Ford remains committed to ensuring the safety of its customers. The company has emphasised that it uses its connected vehicle database to identify other models with the stored diagnostic trouble code (DTC) believed to be related to the brake issue. Ford's Field Review Committee approved the recall on July 18, and the automaker is confident that the software update will address the problem effectively.

Thousands of Ford vehicles are being recalled due to an issue that disables the power brake system