Ford Recalls F-150 Lightning Over Brake Defect originally appeared on Autoblog.
Ford has issued a safety recall for five 2025 F-150 Lightning trucks due to a potential brake fluid leak caused by a faulty repair procedure at the final assembly plant. While the number of affected vehicles is small, the consequences of the defect could be serious — including extended stopping distances and increased crash risk.According to documents filed with the National Highway Traffic Safety Administration (NHTSA), the problem stems from improperly repaired front brake jounce hose bracket screws. These screws may loosen and detach, causing the hose to rub against the tire, eventually leading to a brake fluid leak.
FordImproper Repair at the Factory
The issue was traced back to April 1, 2025, when Ford’s offline repair team began using an unapproved process to fix stripped screw holes on certain F-150 Lightnings. That process, which involved securing the brake hose bracket to the frame, failed to meet Ford’s internal durability standards. The company halted the procedure on May 5 and began investigating.By mid-May, Ford had quarantined affected trucks still at the factory and launched a full review. The automaker determined that five trucks had already been shipped to dealers in the U.S. before the problem was identified. None were built in VIN order, meaning customers will need to check with Ford or a local dealer to verify whether their truck is part of the recall.
FordWarning Signs and Repair Plan
Ford says owners may notice increased brake pedal travel and reduced deceleration. If the brake fluid leak progresses, the red brake warning light will illuminate on the dash. In a worst-case scenario — rapid fluid loss or complete depletion — the vehicle could require significantly more distance to stop.Fortunately, Ford says it is unaware of any accidents, injuries, or warranty claims related to the issue.Owners will be notified by mail starting July 14, with repairs offered free of charge. Dealerships will inspect both front jounce hose brackets and replace the existing screws with a new MR12X40 self-tapping screw (part number W505286-S439) as per Ford’s latest technical instructions. Dealers were notified on July 2.
FordA Precision Fix for a Precision Truck
While the scope of this recall is tiny compared to others — just five vehicles — Ford’s rapid investigation and transparent filing underscore how even minor manufacturing deviations can trigger safety concerns, especially on vehicles with electric powertrains and regenerative braking systems.TheF-150 Lightning has seen price cutsin the past, along with fresh competition in the full-size electric pickup space. Still, Ford continues refining its approach — and has responded quickly to small production flaws to maintain trust in its EV flagship.
Ford Recalls F-150 Lightning Over Brake Defect first appeared on Autoblog on Jul 7, 2025
This story was originally reported by Autoblog on Jul 7, 2025, where it first appeared.
