Karmactive Team
Ford’s hitting the brakes on 312,120 vehicles. The recall became public on August 1 when NHTSA posted the filing dated July 25, 2025 that a fault in the Electronic Brake Booster (EBB) system could leave drivers struggling with longer stopping distances and diminished brake performance.
The recall blankets five top-selling 2025 models: the F-150 pickup (217,969 units), Bronco SUV (39,913), Expedition SUV (26,582), Ranger pickup (20,552), and Lincoln Navigator luxury SUV (7,104). NHTSA’s tracking the campaign under recall number 25V488, while Ford’s internal designation is 25S77.
At the heart of the problem: a Robert Bosch LLC-supplied Electronic Brake Booster that can suddenly enter a “faulted state” during regular driving or when ADAS features are active. When this happens, drivers lose power brake assist until completing a full vehicle shutdown cycle. Dashboard warnings and chimes alert drivers, but many might be caught off-guard by the abrupt change in pedal feel and braking performance.
🚗 Recall Challenge!
Test your knowledge of Ford’s 312,120-vehicle brake-assist recall.
1. Which 2025 model had the highest number of units recalled?
2. What component is at fault?
3. When did Ford’s RRT first log trouble codes?
The fault surfaced May 14 when Ford’s Rapid Response Team logged trouble codes from a company-leased vehicle. By May 22, the issue landed on the desk of Ford’s Critical Concern Review Group, which dug into connected vehicle data through June. The investigation revealed 37 warranty claims tied to the EBB fault, plus one no-injury accident.
Production dates for affected vehicles range from late 2023 to mid-2025: F-150s built between May 8, 2024 and June 9, 2025; Broncos from May 31, 2024 to June 17, 2025; Expeditions from November 8, 2023 to June 9, 2025; Rangers from February 5, 2024 to June 20, 2025; and Navigators from November 9, 2023 to June 9, 2025.
Unlike old-school vacuum boosters, the EBB uses electric motors and sophisticated software to translate pedal pressure into stopping power. When the EBB fails, drivers must push much harder on the pedal for the same braking effect – a dangerous scenario when every foot counts in emergency stops. The risk spikes when ADAS systems are engaged, as adaptive cruise control and collision mitigation systems rely on consistent brake response.
Ford’s fix involves a software update rather than hardware replacement – either pushed over-the-air to connected vehicles or installed during dealer visits. Both options come free of charge. Though technically the vehicles still meet Federal Motor Vehicle Safety Standards (FMVSS 105, 126, and 135) even with reduced braking capability, the increased stopping distances warranted recall action.
The software-based fix reflects the industry’s dramatic shift toward digital solutions for mechanical problems – a trend gaining momentum since electronic throttle control became mainstream in the early 2000s. For consumers, this means faster fixes without component replacements, but raises questions about software reliability in safety-critical systems.
This recall joins a string of brake-related Ford campaigns in 2025, including May’s 273,789-vehicle recall for bent front brake lines causing potential leaks and June’s 2,345-truck “do not drive” warning for Super Duty brake booster pushrods.Owner notification letters are scheduled to be mailed between August 25 and August 29, 2025, but owners can check their VIN at safercar.gov or Ford’s recall website immediately. Those with connected vehicles should enable Ford’s OTA update system via the FordPass app. Others can schedule free dealer service by calling 1-866-436-7332.
