Ford Motor Company has issued a safety recall for 679 vehicles across its 2025 model year lineup due to a potential failure in the electronic brake booster (EBB) system. The defect involves a fault state that can lead to an unexpected loss of power brake assist while driving or during the operation of Advanced Driver Assistance Systems (ADAS). This condition significantly increases the risk of a crash by extending stopping distances or preventing expected braking performance during ADAS engagement.
Highlights
- Affected Vehicles: 2025 Ford F-150, Bronco, Ranger, Expedition, and Lincoln Navigator.
- Safety Risk: Loss of power brake assist can extend stopping distances and compromise ADAS functionality.
- Component Issue: A manufacturing deviation in the EBB integrated circuit causes unintended fail-safe mode activation.
- Remedy: Dealers will replace the suspect EBB module with a new unit free of charge.
Defect Description and Technical Cause
The recall addresses a design flaw in the integrated circuit manufacturing process within the electronic brake booster module. This flaw resulted in unintended manufacturing variations, specifically a mismatch in gain resistors within the EBB pump motor.
While the resistor mismatch itself remained within specification limits, significant variation combined with specific speed-dependent conditions can trigger the module to erroneously enter a fail-safe mode. This action inhibits the activation of the EBB. When this state occurs, the vehicle loses power brake assist.
Drivers will experience a change in brake pedal feel and increased pedal travel. The front brakes will revert to non-boosted hydraulic assist, while the electric park brakes will activate to provide supplemental braking to the rear wheels.
Identifying Warning Signs
Operators will receive immediate feedback if the EBB module enters a fault state. The instrument cluster will display illuminated telltales for the Anti-lock Brake System (ABS), Electronic Stability Control (ESC), and Brake system. Additionally, informational messages will cycle through the cluster display, accompanied by an audible alert.
Vehicle Population and Production Dates
The recall affects 679 units globally, with an estimated 1% defect rate among the population. The affected vehicles were not produced in VIN order, so owners must rely on specific VIN lookups. The specific models and production windows are:
- 2025 Lincoln Navigator: June 13, 2025 – October 27, 2025 (5 units).
- 2025 Ford Ranger: January 22, 2025 – October 23, 2025 (79 units).
- 2025 Ford Bronco: January 22, 2025 – October 28, 2025 (102 units).
- 2025 Ford Expedition: June 11, 2025 – October 11, 2025 (17 units).
- 2025 Ford F-150: November 12, 2024 – November 17, 2025 (476 units).
Chronology and Remedy Program
Ford was first notified of the issue by its Tier-1 supplier, Robert Bosch LLC, on September 25, 2025, following a failure identified in a warranty return part from a 2025 F-150. Investigations by Ford’s Critical Concern Review Group (CCRG) attributed the failure to the integrated circuit variation discussed above. As of November 13, 2025, Ford is aware of three warranty claims but no accidents or injuries related to this defect.
Owners will be notified by mail, with interim letters expected to go out by December 19, 2025. A second letter will follow in late January 2026 once parts are available. Dealers will replace the affected EBB modules with new units manufactured with corrected integrated circuits.
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