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Ford Motor Company has issued an urgent safety recall for 2,345 of its 2025 model year Super Duty trucks due to a manufacturing defect that could cause a sudden loss of brake function. The National Highway Traffic Safety Administration (NHTSA) has issued a “Do Not Drive” advisory for the affected vehicles until a necessary repair has been completed. The defect involves a missing component in the brake pedal assembly, which can lead to brake failure and increase the risk of a crash.
Key Highlights
- Defect: The brake booster pushrod retaining spring may not have been installed on certain vehicles. This can cause the pushrod to disconnect from the brake pedal, resulting in a sudden loss of braking ability.
- Safety Risk: A sudden loss of brake function while driving significantly increases the risk of a crash. Ford has stated there are no warning signs before the failure occurs.
- Affected Vehicles: The recall affects 2,345 Super Duty trucks built between March 19, 2025, and May 4, 2025, including:
- 2025 Ford F-250 SD (1,304 units)
- 2025 Ford F-350 SD (807 units)
- 2025 Ford F-450 SD (132 units)
- 2025 Ford F-550 SD (102 units)
- Remedy: Owners are advised not to drive their vehicles until they are repaired. Ford dealers will inspect the brake pedal assembly and perform necessary repairs free of charge.
- Notifications: Owner notification letters are scheduled to be mailed between June 18, 2025, and June 23, 2025. The recall number is 25C26.
Recall Details and Safety Risk
The recall, filed with NHTSA as campaign number 25V401, addresses a critical safety issue where the brake pedal assembly may be missing its retain spring. This spring is essential for securing the brake booster pushrod to the brake pedal. If the spring is absent, the pushrod can detach, leading to a complete loss of function in the service brakes.
This condition means the vehicles do not comply with Federal Motor Vehicle Safety Standard (FMVSS) Nos. 135 (Light vehicle brake systems) and 105 (Hydraulic and electric brake systems). As of June 4, 2025, Ford was aware of three field reports and one warranty claim related to the issue but reported no accidents or injuries.
Cause of the Defect
An investigation by Ford’s Critical Concern Review Group traced the problem to the Kentucky Truck Plant. The issue was first reported on May 5, 2025, when a dealer technician discovered a freely swinging brake pedal during a pre-delivery inspection of an F-350. The investigation found that the operation was performed by an employee who was new to the role and in training. Compounding the issue, the camera verification system used to ensure parts are correctly installed was down for certain periods, and in other cases, the images lacked the clarity to confirm the spring’s presence. The population of recalled vehicles was determined by identifying units built during the operator’s training period where camera evidence was missing or unconfirmed.
Owner Instructions and Remedy Plan
Ford is urging owners of the affected Super Duty trucks to immediately stop driving their vehicles. Owners should contact a Ford or Lincoln dealer to schedule an inspection. The dealer will examine the brake pedal assembly and, if necessary, install the required components to ensure the brake system is correctly assembled. This service will be provided at no cost to the vehicle owner.
Mailing of owner notification letters is expected to begin on June 18, 2025. Owners can also contact Ford’s customer service line at 1-866-436-7332 or check for their vehicle’s inclusion in the recall by contacting a local dealer.
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