Ford Motor Company is recalling nearly 16,000 model year 2025 Transit vehicles due to a missing cotter pin in the brake booster assembly. The defect can cause the brake booster pushrod to separate from the brake pedal, resulting in a complete loss of braking function. NHTSA has issued a “Do Not Drive” advisory for affected vehicles under recall campaign 26V090.
Highlights
- Ford is recalling 15,965 Transit vans produced between January 21 and April 25, 2025, at the Kansas City Assembly Plant.
- A missing cotter pin may allow the brake booster pushrod to disconnect from the brake pedal, causing total brake failure.
- NHTSA issued a “Do Not Drive” warning, advising owners to park their vehicles until repairs are completed.
- The recall violates FMVSS No. 105, which requires all mechanical braking components to remain intact and functional.
Defect Details and Safety Risk
The affected Transit vehicles may have left the factory without a cotter pin securing the brake booster pushrod to the brake pedal. Additionally, a subsequent assembly step meant to install a redundant retainer clip failed to catch the missing pin.
Without the cotter pin, the pushrod can detach from the pedal during driving. As a result, the driver would lose braking capability entirely. Ford estimates that approximately 1% of the recalled population actually contains the defect.
The issue represents a noncompliance with FMVSS No. 105, Section S5.6. That standard requires all mechanical components of the braking system to remain intact and functional at all times.
How Ford Discovered the Problem
Ford’s Critical Concern Review Group (CCRG) began investigating on December 11, 2025. A manufacturing team at the Kansas City Assembly Plant flagged a warranty report involving a missing brake booster pushrod cotter pin on a 2025 Transit.
In that initial report, the vehicle owner described warning lights appearing on the dashboard. The dealer technician then found the missing cotter pin during inspection and installed both the pin and a redundant retainer clip.
By January 5, 2026, an extended record search uncovered three total reports of missing cotter pins and retainer clips. The root cause remains under investigation. However, Ford’s review indicates the parts were likely omitted during the assembly process.
Warranty and Field Report Data
As of January 20, 2026, Ford identified the following reports related to this condition:
- Three warranty reports and two field reports received between April 4 and December 20, 2025
- Three unique VINs affected across all reports
- No accidents or injuries reported in connection with the defect
Ford’s Field Review Committee approved the recall action on February 10, 2026.
Involved Components
Two components are central to this recall:
- Redundant Clip (Part No. YC1Z-7D256-A) — described as a forward clutch ring
- Pedal Cotter Pin (Part No. BK2Z-16K262-A) — the primary fastener securing the pushrod to the brake pedal
Both parts are OEM-manufactured by Ford at its Dearborn, Michigan facility.
Remedy and Owner Notification
Ford will inspect and repair the brake booster assembly at no charge to owners. The remedy involves verifying the presence of the cotter pin and installing it along with the redundant retainer clip if missing.
Key dates for the recall timeline include:
- February 18, 2026 — Dealer notification and VINs searchable on NHTSA.gov
- March 2–6, 2026 — Owner notification letters mailed
Owners are advised not to drive their vehicles until the repair has been completed. For more information, contact Ford customer service at 1-866-436-7332 and reference recall number 26C07.
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