Some 2016-2018 F-150 and 2016-2017 Expedition/Navigator vehicles may require pressure bleeding of the brake system. The brake system pressure bleeding procedure in the Workshop Manual (WSM), Section 206-00, has been updated to add a warning to not apply the brake pedal or master cylinder damage may occur.
full bulletin at NHTSA ↗2016 Ford Expedition brakes problems
moderate Owners of the 2016 Ford Expedition have filed 46 NHTSA complaints about the brakes, typically surfacing around 61,000 miles at roughly $450 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See brakes across all vehicles →
Failure mileage
Complaints
46
Recalls
0
Avg fix
$450
| Model year | brakes complaints |
|---|---|
| 2013 Expedition | 4 |
| 2015 Expedition | 8 |
| 2016 Expedition (this page) | 46 |
| 2017 Expedition | 67 |
| 2018 Expedition | 4 |
| 2019 Expedition | 3 |
| 2020 Expedition | 4 |
When does it fail?
Of the 46 brakes complaints filed for the 2016 Ford Expedition, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 46 brakes complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Among the 16 model years of Ford Expedition in our records for brakes problems, this one ranks #2 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering brakes on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Some 2013-2018 F-150/Expedition/Navigator vehicles equipped with 4-wheel drive (4WD) may exhibit an intermittent grinding noise while driving in 2-wheel drive (2WD) mode most commonly on acceleration. This may be due to a loss of vacuum to the integrated wheel end (IWE) actuators and/or wear of the IWE components. To correct the condition, follow the Service Procedure steps to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components.
full bulletin at NHTSA ↗SOME 2008-2017 FORD/MERCURY/LINCOLN VEHICLES EQUIPPED WITH SYNC MAY GENERATE A VHR THAT IDENTIFIES A CONCERN WITH THE BRAKES AND SUSPENSION CATEGORY INDICATING SERVICE IS REQUIRED DUE TO A BRAKE SYSTEM WARNING LAMP BEING ILLUMINATED. IF THE PARK BRAKE WAS APPLIED WHEN THE VHR WAS GATHERING DATA FROM THE MAJOR VEHICLE SYSTEMS, THE BRAKES AND SUSPENSION MESSAGE WILL BE REPORTED AS THE VHR LOOKS FOR ANY WARNING LAMPS ILLUMINATED IN THE INSTRUMENT CLUSTER. RERUN THE VHR WITH THE ENGINE ON AND VEHICLE IN PARK, AND ENSURE THE PARK BRAKE IS DISENGAGED. IF THE SYNC VHR IS STILL REPORTING A CONCERN TO THE CUSTOMERS SYNC OWNERS ACCOUNT, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTION FOR DIAGNOSIS BY
full bulletin at NHTSA ↗SOME 2008-2017 FORD/MERCURY/LINCOLN VEHICLES EQUIPPED WITH SYNC MAY GENERATE A VHR THAT IDENTIFIES A CONCERN WITH THE BRAKES AND SUSPENSION CATEGORY INDICATING SERVICE IS REQUIRED DUE TO A BRAKE SYSTEM WARNING LAMP BEING ILLUMINATED. IF THE PARK BRAKE WAS APPLIED WHEN THE VHR WAS GATHERING DATA FROM THE MAJOR VEHICLE SYSTEMS, THE BRAKES AND SUSPENSION MESSAGE WILL BE REPORTED AS THE VHR LOOKS FOR ANY WARNING LAMPS ILLUMINATED IN THE INSTRUMENT CLUSTER. RERUN THE VHR WITH THE ENGINE ON AND VEHICLE IN PARK, AND ENSURE THE PARK BRAKE IS DISENGAGED. IF THE SYNC VHR IS STILL REPORTING A CONCERN TO THE CUSTOMERS SYNC OWNERS ACCOUNT, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTION FOR DIAGNOSIS BY
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners describe sudden, catastrophic brake failure where the pedal sinks to the floor with no resistance. The low brake fluid warning light typically illuminates shortly before complete loss of braking pressure. Critically, the brake fluid reservoir empties despite no visible leaks under the vehicle, under the hood, or at the wheels—a pattern that repeats even after owners refill the reservoir.
Mechanics and Ford dealers consistently diagnose the same root cause: the brake master cylinder's internal seal fails, allowing fluid to leak directly into the vacuum brake booster chamber instead of escaping externally. The booster then becomes contaminated with brake fluid, and both components fail together.
Failures have occurred at mileages ranging from 21,000 to 140,000 miles, often without advance warning beyond the low-fluid light. Several owners report narrowly avoiding collisions because they were traveling at low speed or downhill when the failure occurred. Owners frequently cite that the 2016 F-150 was recalled for this identical defect (NHTSA 20V332000, Ford 20S31, later expanded to Campaign 22V150000), yet their Expeditions—which use the same master cylinder and booster parts—were initially denied coverage. Repair costs range from $1,062 to $1,500 for the paired master cylinder and booster replacement. Some owners reported delays obtaining recall-required parts, with dealers unable to perform the repair for weeks or months.
Same Ford Expedition brakes reports on nearby years: 2017
Failure modes owners describe
Master Cylinder Internal Failure with Brake Booster Fluid Contamination
The master cylinder seal fails, allowing brake fluid to leak internally into the vacuum brake booster. The fluid does not appear under the vehicle or at wheel cylinders because it enters the booster chamber instead. The reservoir empties completely over hours or after repeated brake applications. Owners refill fluid only to watch it drain again with no visible external leak.
When: Occurs at various mileages (21,000 to 140,000 miles reported; cluster includes failures at 37,222, 50,450, 56,511, 60,000, 62,000, 96,000, 102,000, 110,000 miles)
Symptoms owners cite: Low brake fluid warning light illuminates; Brake pedal loses resistance and sinks to the floor; Complete loss of service brake pressure; Fluid reservoir drains with no external leaks visible; Spongy brake feel that worsens with each application; Brake fluid leaks into booster visible only upon disassembly
Repairs/costs cited: Requires replacement of both brake master cylinder and brake booster as a paired assembly. Repair quotes cited: $1,500 and $1,062.62. Some owners report dealer parts unavailability delays of days to weeks.
Recalls/TSBs owners mention: NHTSA Campaign 22V150000 (Service Brakes, Hydraulic) issued for 2016 Expedition. Some complaints note parts unavailable for recall repair. Owners reference NHTSA Campaign 20V332000 and Ford recall 20S31 for 2015–2016 F-150 with identical master cylinder/booster design. Several owners report Ford initially denied their Expedition was covered despite recall applicability.
Brake Booster Vacuum Failure
The brake booster fails to maintain vacuum, rendering it unable to assist brake application. One complaint specifically mentions vacuum pump failure; another describes booster 'drinking' brake fluid when master cylinder fails. Booster failure may occur in conjunction with master cylinder failure or independently.
When: Reported on leased vehicle in early 2016 (January–February); other cases show concurrent failure with master cylinder at various mileages
Symptoms owners cite: Brake pedal requires excessive force to engage; Complete loss of brake power assist; Hard brake pedal with no boost; Booster chamber fills with brake fluid instead of vacuum
Repairs/costs cited: Vacuum pump and booster assembly replaced in at least one case. Full booster replacement typically required when contaminated with brake fluid.
Master Cylinder Cracking/Structural Failure
The master cylinder develops internal cracks or structural defects, causing rapid fluid loss into the booster or other non-visible areas. One complaint explicitly states the cylinder was found cracked upon mechanic inspection.
When: Occurs at low to high mileages; one report at 21,000 miles
Symptoms owners cite: Brake fluid reservoir empties without external leakage; Low brake fluid warning lights; Sudden or progressive loss of brake pressure; White smoke/clouds from exhaust in one case
Repairs/costs cited: Requires master cylinder replacement. One owner reported the cylinder 'fractured' per Ford service line diagnosis.
Hydraulic Control Unit Failure (Post-Recall)
A secondary brake system failure that occurs after the master cylinder/booster recall repair has been completed. The HCU fails to regulate brake pressure, causing brake loss or malfunction during driving.
When: Reported after recall repair completion (110,000 miles in one case)
Symptoms owners cite: Brakes fail to engage despite pedal application; Vehicle unable to stop at desired deceleration rate; Brake failure occurs after previous recall repair was done
Repairs/costs cited: Requires HCU replacement. Ford has not covered this repair under the existing recall.
Recalls/TSBs owners mention: Ford declined to cover the HCU failure under NHTSA Campaign 22V150000, claiming the vehicle is not covered by the recall despite prior repair under that same campaign.
Synthesized from 46 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
The contact owns a 2016 Ford Expedition. The contact stated that while starting the vehicle, a burning odor was detected. The contact later received notification of NHTSA Campaign Numbers: 22V150000 (Service Brakes, Hydraulic) and 22V648000 (Visibility, Electrical System). The vehicle was taken to the dealer, where it was diagnosed that the front blower motor connector and resistor needed to be…
When merging on the highway in the rain the vehicle locked up on me and almost killed me. I could have been seriously injured I could not stop the car and it slid along the highway at high speeds . Luckily was able to get to the shoulder
Braking ability went to 0% while driving; accompanied by a "brake fluid is low" dashboard indicator light (dashboard lamp became lit after braking applied ). When brakes were applied there was 0% available to slow/stop the vehicle (in heavy traffic). Driver was able to avoid a crowded intersection and a red light to my vehicle traffic direction (red light to me) by applying the parking brake and…
Had brakes trouble with your 2016 Ford Expedition?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the brakes problem on the 2016 Ford Expedition?
It's a documented issue but not catastrophic. 46 complaints have been filed. Repairs average $450 and most owners catch it before it causes a breakdown.
At what mileage does the brakes typically fail?
Across the 32 complaints that reported odometer mileage, most brakes failures cluster between 50,450 and 80,000 miles, with the median around 61,000. A quarter of owners report trouble before 50,450; a quarter make it past 80,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $450 for brakes repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to brakes?
No active recalls currently cover brakes issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2016/Ford/Expedition.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.