Latest Updates
Ford announced on February 26, 2026 that it is recalling 15,965 model year 2025 Transit vehicles because the brake pedal may disconnect from the brake booster pushrod, resulting in total loss of braking function. [1] The NHTSA issued a “Do Not Drive” advisory, ordering owners to immediately stop operating affected vans until repairs are completed. [2] [3]
Assembly Plant Defect
The Kansas City Assembly Plant manufactured Transit vans between January 21, 2025 and April 25, 2025 without installing brake booster pushrod cotter pins and redundant retainer clips. These components secure the brake pedal connection to the brake booster pushrod, and their absence allows the pedal to separate completely from the braking system during operation.
Brake System Failure
Without the cotter pin securing the connection between the brake pedal and brake booster pushrod, the pedal can disconnect entirely while driving. When this separation occurs, drivers lose all braking capability, rendering the brake pedal completely nonfunctional and leaving no method to slow or stop the vehicle.
Drivers may notice a “loose” or “wobbly” brake pedal feel if the cotter pin is missing or improperly installed. However, complete disconnection can occur suddenly without warning, causing catastrophic brake failure at any speed.
Federal Safety Violation
Transit vans manufactured without properly installed brake booster components violate Federal Motor Vehicle Safety Standard (FMVSS) No. 105, which governs hydraulic and electric brake systems. Section S5.6 of FMVSS 105 specifically requires brake system integrity, which Ford failed to maintain during the assembly process.
Discovery Timeline
On December 11, 2025, Kansas City Assembly Plant staff discovered a 2025 Transit without the brake booster pushrod cotter pin and reported the issue to Ford’s Critical Concern Review Group. By January 5, 2026, extended record searches identified three field reports of missing cotter pins and retainer clips on 2025 Transit vehicles.
Ford’s investigation determined that the assembly process failed to install these critical safety components during manufacturing. The last field report alleging this condition was filed on December 20, 2025, approximately two months before Ford announced the recall.
No Crashes Yet Reported
Ford states it is not aware of any accidents or injuries attributed to brake pedal disconnection as of the recall filing date. However, the company estimates approximately 1 percent of recalled vehicles—roughly 160 units—actually have the missing components.
Remedy Requirements
Dealers will inspect brake booster assemblies to verify whether cotter pins and retainer clips are properly installed. If components are missing or damaged, dealers will install all required parts at no charge to vehicle owners.
Ford offers mobile service and dealer-coordinated towing to ensure repairs are completed safely without requiring owners to drive unsafe vehicles. Notification letters were mailed between March 2 and March 6, 2026, with VINs searchable on the NHTSA database since February 18, 2026.
Commercial Impact
The 2025 Ford Transit dominates the American large van segment, serving as the primary workhorse for countless commercial operations, delivery services, and fleet operators. A “Do Not Drive” order affecting nearly 16,000 commercial vehicles creates significant business disruptions, forcing companies to idle entire portions of their fleets during the repair process.
Manufacturing Negligence
Ford’s assembly line quality control failed to detect missing brake components during multiple stages of the manufacturing process. The company missed opportunities to identify the defect during initial assembly, during a subsequent operation designed to install redundant retention clips, and during final vehicle inspections before shipping to dealers.
Legal Claims
Vehicle owners may pursue strict products liability claims alleging Ford manufactured defective brake systems that failed to meet federal safety standards. Manufacturing defect claims assert the Kansas City Assembly Plant deviated from proper assembly procedures by omitting critical safety components.
Negligence claims can allege Ford breached its duty to implement adequate quality control measures to detect missing brake components before vehicles left the factory. Design defect claims may assert Ford’s brake assembly design relies on easily-omitted components without adequate fail-safes to ensure proper installation.
Business Interruption Damages
Commercial fleet operators may recover economic losses from business interruptions caused by mandatory vehicle removal from service. Lost revenue from halted delivery operations, rental vehicle costs for replacement transportation, and employee downtime constitute compensable damages.
Diminished Value Claims
Transit vans subject to “Do Not Drive” recalls suffer diminished resale value even after repairs are completed. Vehicle history reports permanently document the brake system defect, affecting future sales prices and marketability to commercial buyers who depend on vehicle reliability.
Contact an Attorney
If you own a 2025 Ford Transit affected by brake pedal disconnection defects, or experienced brake failure requiring emergency repairs, contact a product liability attorney. Document all business losses, rental vehicle expenses, and communications with Ford regarding the “Do Not Drive” order.
References
1. https://www.ksat.com/news/local/2026/03/02/more-than-15000-ford-vehicles-recalled-due-to-brake-pedal-failure/
2. https://www.fromtheroad.ford.com/us/en/articles/2026/2025-transit-advisory
3. https://www.caranddriver.com/news/a70513450/ford-4-million-vehicle-trailer-brake-recall/