CHICAGO — Ford Motor Company announced a recall of 1.2 million F-150 pickup trucks Sunday after discovering a brake system defect that could cause sudden loss of braking power. The recall covers model years 2021 through 2024 and stems from a faulty electronic brake control module. Drivers may experience a delayed response or complete failure when pressing the brake pedal.
The National Highway Traffic Safety Administration opened an investigation in February after receiving 298 complaints of unintended brake activation or failure. At least six crashes and three minor injuries have been linked to the issue so far. This marks Ford’s largest recall of the year and the third major F-150 recall since 2023.
Brake module software triggers the fix
Ford says the problem lies in the software governing the brake system’s hydraulic control unit. A communication error between the module and the truck’s onboard computer can cause the brakes to engage unexpectedly — or not engage at all. The company traced the defect to a supplier’s manufacturing variance that affects roughly 1.4% of the affected vehicles.
Dealers will update the brake control software free of charge. Ford expects to begin notifying owners by June 15. The fix takes about 45 minutes. Owners can check their vehicle’s status using Ford’s online recall portal.
“This is a serious safety issue because it erodes driver confidence in a fundamental vehicle system,” said Maria Torres, Director of Automotive Safety Research at the Center for Auto Safety. “When a driver presses the brake pedal, they need immediate and predictable response. Anything less creates real risk on the road.”
Impact stretches across the F-150 lineup
The recall includes all F-150 trims — from the base XL work truck to the high-end Limited and Raptor models. Ford also included the all-electric F-150 Lightning in the recall, though the company says the EV’s regenerative braking system operates independently and remains unaffected. Still, the brake control module failure can still disable the Lightning’s hydraulic brakes entirely.
Ford shares dipped 2.3% in premarket trading Monday. Analysts estimate the recall will cost the company between $180 million and $250 million. That figure covers parts, labor, and customer outreach. It doesn’t include potential legal settlements — at least three class-action lawsuits have already been filed in Michigan and Texas.
The recall comes at a tough time for Ford. The company just posted a $1.2 billion loss in its EV division last quarter. And the F-150 remains Ford’s best-selling vehicle — accounting for nearly 40% of the company’s North American revenue. Losing customer trust in that truck could sting for years.
“Ford needs to communicate clearly and act fast to contain the damage here,” said Derek Nakamura, Senior Automotive Analyst at LMC Automotive. “The F-150 isn’t just a product — it’s the backbone of their brand. Every day this story dominates headlines, it chips away at the loyalty they’ve built over decades.”
Ford has not announced a stop-sale order on new F-150s. Dealers can still sell existing inventory, but must disclose the recall to buyers. Some dealers report customers walking away from deals after hearing about the brake issue.
The NHTSA says it will monitor the recall’s effectiveness. If the software update doesn’t resolve the problem, the agency could demand a more extensive — and expensive — hardware replacement. For now, Ford urges owners to schedule service immediately if they notice any brake hesitation or unexpected engagement.
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