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Cotter pins essential to brake functions may be missing from some Ford vehicles produced last year.
WASHINGTON — Ford Motor Company is recalling nearly 16,000 vans because a missing component could lead to a loss of braking function and increase the risk of a crash, federal safety regulators said.
The company has issued a “Do Not Drive” advisory for the cars because they could fail to stop.
The National Highway Traffic Safety Administration published a recall notice Feb. 18 covering 15,965 model year 2025 Ford Transit vehicles produced between Jan. 21 and April 25, 2025.
The notice states certain vehicles may have been assembled without a cotter pin that secures the brake booster pushrod to the brake pedal, potentially allowing the pushrod to separate and impair braking. In layman’s terms, a critical component of the braking system on the vehicles may be missing, meaning the affected vehicles would be unable to brake.
How the issue was identified
According to recall documents, the issue was first raised Dec. 11, 2025, when a manufacturing team at the Kansas City Assembly Plant alerted Ford’s internal review group after a warranty report described dashboard warning lights. A dealer inspection found the cotter pin missing from the brake pedal assembly. Technicians were able to install the pin and a retainer clip to fix the issue with that particular car.
An expanded records search completed on Jan. 5, 2026 identified three reports of missing cotter pins and retainer clips on 2025 Transit vans. Investigators said the parts may not have been installed during a period of assembly variability, though the root cause remains under review.
Ford said it is aware of three warranty reports and two field reports tied to the issue, involving three unique vehicles, received between April and December 2025.
Ford said it has no reports of crashes or injuries related to the defect.
What to do if you own a Ford Transit
If the brake booster pushrod disconnects, it can reduce or eliminate braking ability, a condition that conflicts with federal standards requiring braking components to remain intact and functional.
Owners are being advised not to drive their vehicles until the cotter pin’s presence is verified. Ford will notify affected owners by mail in March and instruct them to schedule an inspection with a Ford or Lincoln dealer. Dealers will inspect and repair the brake booster assembly as needed at no cost.
Transit owners can also contact Ford customer service at 1-866-436-7332 and reference the recall number 26C07.
The NHTSA has also made Vehicle Identification Numbers (VINs) involved in this recall searchable on NHTSA.gov.
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