Safety Recall 22S11 – Brake Master Cylinder Replacement – 2016-2017 Ford Expedition, Lincoln Navigator, & 2016-2018 F-150

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March 11, 2022 NHTSA CAMPAIGN NUMBER: 22V150000

Brake Master Cylinder May Leak Fluid into Booster

A loss of brake fluid may result in a change in brake pedal travel, increased pedal effort and reduced front brake function, requiring greater effort and distance to stop the vehicle. These conditions can increase the risk of a crash.

 

NHTSA Campaign Number: 22V150

Manufacturer Ford Motor Company

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 195,864

 

Summary

Ford Motor Company (Ford) is recalling certain 2016-2017 Ford Expedition, Lincoln Navigator, and 2016-2018 F-150 vehicles equipped with 3.5L Ecoboost engines. The brake master cylinder may allow brake fluid to leak from the front wheel circuit into the brake booster.

 

Remedy

Dealers will replace the brake master cylinder. If the master cylinder is leaking, the brake booster will also be replaced. Repairs will be performed free of charge. An interim owner notification letter notifying customers of the safety defect were mailed on April 29, 2022. Owner notification letters were mailed April 29, 2022. This recall is an expansion of NHTSA recall number 20V-332. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S11.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


May 17, 2022

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD –
Safety Recall 22S11 – Supplement #1
Certain 2016, 2017 and 2018 Model Year F-150, 2016-2017 Model Year Expedition and 2016-
2017 Model Year Lincoln Navigator Vehicles Equipped with 3.5L Ecoboost Engines
Brake Master Cylinder Replacement

 

REASON FOR THIS SUPPLEMENT

  • Affected Vehicles and Build Dates: F-150 vehicles were incorrectly listed as only including 2017 model year. 2016 and 2018 model years have been added to the program. While the affected F-150 build date ranges in the original bulletin did not expand, they have been added to accurately reflect all affected vehicles.
  • PARTS REQUIREMENTS / ORDERING INFORMATION: 2016 F-150 brake booster part number has been added, and model years added. This part requires a contact be sent to the SSSC for ordering.

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
F-150 2016 Dearborn Truck August 2, 2016 through September 27, 2016
2017 August 2, 2016 through January 31, 2017
2018 January 5, 2017 through January 26, 2017
2016 Kansas City August 2, 2016 through October 15, 2016
2017 August 2, 2016 through January 31, 2017
Expedition  Navigator 2016-2017 Kentucky Truck July 20, 2015 through January 31, 2017

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, a seal in the rear of the brake master cylinder may become compromised, allowing brake fluid to leak into the brake booster. If the brake fluid reservoir is depleted below a predetermined level, the driver will be alerted that brake system service is required by a combination of the following:

  • An audible chime
  • A full screen message center alert
  • Illumination of the red brake warning indicator

If the brake fluid reservoir continues to be depleted, the driver may experience a change in brake pedal travel and feel, and reduced brake function in the front wheels without affecting brake function in the rear wheels. Reduced brake function in the front wheels can extend stopping distance, increasing the risk of a crash.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to replace the brake master cylinder. If indications of a leak are present between the brake master cylinder and brake booster, dealers are also to replace the brake booster. This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of April 25, 2022. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

 

SOLD VEHICLES

  • Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable. Owners can continue to safely drive their vehicles.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this recall.

 

OWNER REFUNDS

  • This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.
  • Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251.
  • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with brake master cylinder and brake booster replacement.

 

RENTAL VEHICLES 

Rental vehicles are not approved for this program.

 

LINCOLN PICKUP AND DELIVERY

Owners of 2017 MY and newer Lincoln vehicles have the option of requesting pickup and delivery service with a Lincoln loaner (up to 2 days), from their dealership. For details, reference EFC08708, 2021 Lincoln Pickup & Delivery Updates.

 

PARTS REQUIREMENTS

Part Number DescriptionF-150 ONLY Order Quantity
JL3Z-2140-A Brake Master Cylinder – use with 22S11B or 22S11C (BRMC-293) 1
PM-20 Safety Recall 22S11 - Brake Master Cylinder Replacement - 2016-2017 Ford Expedition, Lincoln Navigator, & 2016-2018 F-150 | small light Dot 4 Brake Fluid (3 required / 4 per sell pack) 1

 

Brake booster parts table – Replace booster ONLY if the master cylinder is leaking at or into the booster. Refer to Attachment III before ordering a booster.

Find correct model and order only one (1) brake booster if the master cylinder is leaking.

Part Number DescriptionF-150 ONLY Order Quantity
HL3Z-2005-G Brake Booster – claim 22S11C (except Raptor)
(2017-2018 Model Years)
1
JL1Z-2005-A Brake Booster – claim 22S11C (ONLY Raptor)
(2017-2018 Model Years)
or
HL3Z-2005-F
3M5Z-2L523-AA Safety Recall 22S11 - Brake Master Cylinder Replacement - 2016-2017 Ford Expedition, Lincoln Navigator, & 2016-2018 F-150 | small light Clevis Pin (All Model Years) 1

 

Part Number Description –F-150 (2016 Model Year ONLY) Order Quantity
GL3Z-2005-H Brake Booster 1

 

PARTS REQUIREMENTS

Part Number DescriptionExpedition / Navigator ONLY Order Quantity
HL1Z-2140-B Brake Master Cylinder – claim 22S11D or 22S11E (BRMC-308) 1
DL3Z-2005-E Brake Booster – claim 22S11E (BRB-146) 1

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Part Number Description – Expedition / Navigator ONLY Order Quantity
PM-20 Safety Recall 22S11 - Brake Master Cylinder Replacement - 2016-2017 Ford Expedition, Lincoln Navigator, & 2016-2018 F-150 | small light Dot 4 brake fluid – all models (3 req. / pkg. of 4) 1
3M5Z-2L523-AA Safety Recall 22S11 - Brake Master Cylinder Replacement - 2016-2017 Ford Expedition, Lincoln Navigator, & 2016-2018 F-150 | small light Clevis pin – all models 1

 


CERTAIN 2016, 2017, AND 2018 MODEL YEAR F-150, 2016-2017 MODEL YEAR EXPEDITION AND 2016-2017 MODEL YEAR LINCOLN NAVIGATOR VEHICLES BRAKE MASTER CYLINDER REPLACEMENT

 

SERVICE PROCEDURE

1. Position the vehicle on a hoist. Please follow the Workshop Manual (WSM) procedures in Section 100-02.

2. Remove the master cylinder. Please follow the WSM procedures in Section 206-06.

3. Inspect the rear of the master cylinder and the mounting surface of the brake booster.

Are there signs of leaking brake fluid? Signs of leaking brake fluid may include fluid on the back of the master cylinder or on the mounting surface of the brake booster, and/or peeling paint on the brake booster. See Figure 1.

Yes  –  Replace the brake booster. Please follow the WSM procedures in Section 206-07, then proceed to Step 4.

No – Proceed to Step 4.

 

4. Install a new master cylinder. Please follow the WSM procedures in Section 206-06.

IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. Unless a part is requested to be returned to Ford, all parts replaced under this FSA must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Refer to the Parts Retention, Return, & Scrapping section of the FSA dealer bulletin for further information.

 


22S11 – CERTAIN 2016-2017 F-150, EXPEDITION AND NAVIGATOR VEHICLES MASTER CYLINDER LEAK
Amendment #2
Chronology

 

In May 2016, Ford issued FSA 16S24 (16V345) for F-150s produced between August 1, 2013 and August 31, 2014 equipped with the 3.5L Ecoboost engine to address brake master cylinder fluid leakage into the booster caused by the rolling of the rearmost cup seal in the master cylinder. When the decision was made, root cause was unknown and a rate-based decision was made based on information available at that time.

 

After continued field data monitoring and discussions with NHTSA, Ford issued 20S31 (20V332) in June 2020, to extend the population for F-150’s equipped with the 3.5L Ecoboost engine produced through August 1, 2016. This is when Hitachi implemented a corrective action, adding a silicone lubricant to the master cylinder seal.  At the time of 20S31 (20V332), Ford understood the data to support the end date for that recall.

 

Ford continued to monitor field reports and communicate with NHTSA for vehicles outside the scope of 20S31.  The monitoring included Ford Expedition and Lincoln Navigator vehicles built during the 20S31 period, which share a similar brake master cylinder design, as well as F-150 3.5L Ecoboost vehicles built after August 1, 2016. At the time of 20S31, field reports were significantly lower for both of those other populations than for the population subject to 20S31.

 

An updated analysis of field data in November 2021 found the report rate for Expedition / Navigator vehicles was approaching 10R/1000 for certain months of vehicle production.  A total of 498 potentially related reports had been received between January, 2016 and November, 2021.  In addition, field data for Expedition / Navigator and F-150 3.5L Ecoboost vehicles produced within several months post-20S31 showed increasing failure rates, though still below the rate for vehicles addressed by 20S31.  A total of 231 potentially related reports had been received between June, 2020 and November, 2021. Ford reviewed this subject with NHTSA on December 8, 2021 and February 7, 2022.  Investigation into supplier records and discussion with the supplier identified additional steps taken by the supplier to further improve brake master cylinder seal installation from August 2016 – December 2016.  These include an automated process to remove imperfect threads from the master cylinder outlet port, as well as actions to improve installation of the rearmost cup seal in the master cylinder. Master cylinders with these improvements were incorporated into vehicle production by January 31, 2017.

 

On March 4, 2022, Ford’s Field Review Committee reviewed the concern and approved a safety recall action.

 

Ford is aware of 4 low speed/low impact accident allegations with no injuries.

 

 


7 Affected Products

Vehicles

MAKE MODEL YEAR
FORD EXPEDITION 2016-2017
FORD F-150 2016-2018
LINCOLN NAVIGATOR 2016-2017

 


16 Associated Documents

Recall 573 Report

RCLRPT-22V150-1267.PDF 215.973KB

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Defect Notice 573 Report

RCLRPT-22V150-7111.PDF 215.973KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S11 Certain 2017 Model Year F-150, 2016-2017 Model Year Expedition and 2016-2017 Model Year Lincoln Navigator Vehicles Equipped with 3.5L Ecoboost Engines Brake Master Cylinder Replacement

RCMN-22V150-3408.pdf 458.773KB

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Recall Acknowledgement

RCAK-22V150-5289.pdf 815.09KB

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Recall 573 Report

RCLRPT-22V150-5861.PDF 215.974KB

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Miscellaneous Document – 22S11 – CERTAIN 2016-2017 F-150, EXPEDITION AND NAVIGATOR VEHICLES MASTER CYLINDER LEAK Chronology

RMISC-22V150-3665.pdf 99.485KB

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Miscellaneous Document – Chronology

RMISC-22V150-8921.pdf 260.567KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V150-5135.pdf 60.491KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V150-0500.pdf 60.63KB

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Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 22S11 – Supplement #1 Certain 2016, 2017 and 2018 Model Year F-150, 2016-2017 Model Year Expedition and 2016-2017 Model Year Lincoln Navigator Vehicles Equipped with 3.5L Ecoboost Engines Brake Master Cylinder Replacement

RCMN-22V150-4118.pdf 535.971KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V150-6587.pdf 60.431KB

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Recall Quarterly Report #1, 2022-2

RCLQRT-22V150-6787.PDF 211.157KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V150-3868.pdf 137.067KB

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Recall Quarterly Report #2, 2022-3

RCLQRT-22V150-0129.PDF 211.259KB

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ISSUED Renotification Notice

RCRN-22V150-6656.pdf 460.406KB

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Recall Quarterly Report #3, 2022-4

RCLQRT-22V150-4446.PDF 211.353KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V150&docType=RCL

 


 

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