Owners describe brake failures ranging from excessive pedal travel to complete loss of stopping power, typically at highway and city speeds. The brake pedal often sinks to the floorboard or requires hard pressure to engage braking. Many failures occur when the ABS system activates, particularly after hitting road surface impacts like potholes. Some drivers report the brake pedal will go soft mid-stop, requiring continued pressure to decelerate.
ABS warning lights frequently illuminate alongside brake failure. In several cases, independent mechanics and dealers have diagnosed faulty hydraulic control units (HCU), master cylinders, power brake boosters, and sticking ABS valves. Some owners had identical repairs performed twice with the failure returning. One owner reported a rubber brake hose rupture near the master cylinder that caused sudden total brake loss.
Multiple owners cite NHTSA recall 19V904000 (Service Brakes, Hydraulic), but many report their VINs are not listed despite displaying the exact failure mode described in the recall. Dealers have repeatedly informed owners that recall repair parts are unavailable, with delays extending from 2019 through at least mid-2020. Owners who pursued independent repairs paid between $700 and $2,000. One vehicle was still sitting at a dealer unrepaired after multiple visits.
Failure modes owners describe
Brake pedal excessive travel / loss of braking pressure
Brake pedal depresses to the floorboard or requires excessive travel before braking is achieved. Drivers report loss of braking ability or severely reduced stopping power, often without warning lights. ABS activation frequently precedes or accompanies the failure.
When: Occurs at various speeds (20–60 mph), sometimes after emergency braking, hitting bumps/potholes, or in wet conditions. Can happen intermittently or recur multiple times.
Symptoms owners cite: Brake pedal sinks to floorboard; Reduced braking response requiring hard pedal pressure; Brake pedal goes soft mid-stop; Excessive pedal travel before braking engages; Loss of all or partial brake pressure
Repairs/costs cited: Owners report replacement of hydraulic control unit (HCU), master cylinder, brake booster, ABS module, brake lines flushed. Some vehicles required HCU replacement twice and failure persisted. Costs cited: ~$700 for HCU repair, $2,000 quoted by dealer.
Recalls/TSBs owners mention: NHTSA Campaign 19V904000 (Service Brakes, Hydraulic) / Recall 19S54 issued. Multiple owners report VINs not included in recall despite exhibiting same symptoms. Parts unavailable for extended periods (delays through at least Q2 2020); no remedy for non-recalled VINs.
ABS system failure with warning lights
ABS warning light and other warning lights (Advanced Trac, Traction Control) illuminate on the instrument panel. Often occurs during braking or low-speed maneuvers. ABS activation may trigger brake pedal collapse.
When: At low speeds (turning) or during emergency braking; can occur intermittently or recur after brief periods of normal operation.
Symptoms owners cite: ABS warning light illuminated; Advanced Trac warning light illuminated; Traction Control warning light illuminated; Multiple unknown warning lights on dashboard; Brake pedal collapse coinciding with ABS activation
Repairs/costs cited: Mechanics diagnosed ABS module failure, HECU (Hydraulic Electronic Control Unit) failure, ABS valve sticking in module. Repairs attempted include ABS module replacement, HECU replacement, hydraulic control assembly replacement.
Recalls/TSBs owners mention: Some cases linked to recall 19V904000 but VINs not included. Manufacturer has provided no specific TSB or extended warranty program for non-recalled vehicles.
Power brake booster and master cylinder failure
Brake booster fails, causing stiff brake pedal that lacks power assist. Often accompanied by hissing noise from behind brake pedal. Master cylinder also fails simultaneously or requires replacement.
When: At 35 mph and various speeds; failure can recur multiple times.
Symptoms owners cite: Stiff brake pedal with no power assist; Hissing noise from behind brake pedal; Vehicle fails to decelerate despite brake application; Recurring failure after repair attempts
Repairs/costs cited: Replacement of power brake booster and master cylinder required. Vehicle not repaired in at least one case.
Rubber brake hose rupture / brake fluid leak
Rubber flex hose attached to or near master cylinder ruptures, causing sudden complete loss of brake pressure. Hose rupture occurs in an area not easily accessible and not near bottom of engine bay where salt/debris exposure is typical.
When: While braking or in stopping situation; complete failure is sudden.
Symptoms owners cite: Loud pop sound followed by complete loss of brake pressure; No braking ability whatsoever
Repairs/costs cited: Brake hose replacement required. Vehicle was out of manufacturer warranty by 2,391 miles when failure occurred.
Recalls/TSBs owners mention: Ford stated no recall applicable. Owner was denied warranty coverage due to mileage over warranty limit.
Intermittent brake loss after road surface contact
Brakes fail intermittently when ABS engages during or after hitting potholes, bumps, or other road surface impacts. Brake pedal collapses to floor when ABS activates, losing pressure and braking ability.
When: After hitting potholes or bumps while approaching a stop; ABS activation coincides with brake failure.
Symptoms owners cite: Brake pedal goes to floor when ABS activates; Loss of brake pressure and braking ability; Multiple near-miss accidents; Blown stop signs and red lights due to brake failure
Repairs/costs cited: Hydraulic control assembly for ABS system replaced. A sticking valve in the ABS module was identified as the cause.
Synthesized from 33 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.