The fifth-generation Expedition showed up for 2025 with a 3.5-liter EcoBoost V6 and a 10-speed automatic. It's a heavy truck that can tow up to 9,600 pounds when set up right, which means its brakes matter more than most. So when the brake warning lights come on, don't shrug it off.
The brake booster recalls
Instead of an old-school vacuum booster, the Expedition uses an electronic brake booster (made by Bosch) to add power to your pedal. Ford found it can enter a faulted state while driving:
| Recall | Vehicles | What goes wrong | Fix |
|---|---|---|---|
| 25V488 (Ford 25S77) | 2025 Expedition, F-150, Bronco, Ranger, Navigator (312,120 total) | Voltage dips can make the booster motor shut down, cutting power assist. It can also fault when a driver-assist feature asks for braking | Free booster software update, over the air or at a dealer. Owner letters mailed August 2025 |
| 25V823 (Ford 25SD4) | 679 of the same 2025 models | Same loss of power brake assist | Dealers replace the electronic brake booster for free |
Ford estimated only about 1% of the trucks in the first recall actually have the defect. But you don't get to pick which 1% you're in. Check your VIN at nhtsa.gov/recalls or call Ford at 1-866-436-7332.
Warning signs to take seriously
Ford's recall report lists what drivers notice when the booster faults:
- The brake pedal feels different and travels further
- ABS, stability control and brake warning lights come on together
- Messages cycle on the cluster and a chime sounds
- It takes longer to stop
NHTSA complaints on the 2025 Expedition describe the same thing. One owner says the pedal went to the floor and the SUV rolled through a stop sign at 25 to 30 mph. Another describes a stream of brake warnings right before the brakes barely responded. Others report the automatic emergency braking slamming on hard with nothing ahead. We found 8 brake-related complaints among 37 filed for the 2025 model when we checked.
Is it the booster, or just worn brakes?
| Symptom | More likely cause |
|---|---|
| Warning lights plus a long, soft pedal | Booster fault. Recall territory |
| Squeal when braking, no lights | Pad wear indicators or dust |
| Grinding | Pads worn to metal. Stop driving soon |
| Steering wheel shakes when braking | Rotor problems |
| Pulling to one side | Sticking caliper or uneven pads |
What brake work costs
| Job | Typical cost |
|---|---|
| Brake booster recall work (25V488 or 25V823) | $0 at a Ford dealer |
| Brake pad replacement, 2025-2026 Expedition | $285 to $342 (RepairPal) |
| Brake pad replacement, 2022-2024 Expedition | $244 to $301 (RepairPal) |
| Front or rear pads at a dealer, 2024 Expedition | $276 to $324 (KBB, one axle) |
Those pad prices assume the rotors are reusable. On a big, heavy SUV that tows, rotors often need replacing along with pads, so ask the shop to measure them and show you the spec before agreeing.
DIY or shop?
Pads on a full-size SUV are doable at home if you own a good jack, jack stands and a torque wrench. But if your truck has an electronic parking brake, the rear calipers usually need a scan tool or a service mode before the pistons will retract. On a new Expedition still under warranty, any warning light should go straight to a dealer anyway.
What to ask before you pay
- "Are recalls 25V488 and 25V823 done on my VIN?"
- "Did the over-the-air update install, and can you confirm it?"
- "What are my pad and rotor measurements?"
- "Are you using Ford pads or aftermarket, and what's the warranty?"
Is it worth fixing?
Brakes are never optional, and the booster recall fixes are free. Get the recall work done, keep the paperwork, and budget a few hundred dollars per axle for normal pad wear on a truck this heavy.
More Expedition help is on the Ford Expedition repair page. Shifting weird too? See our Expedition 10-speed guide. Prices checked October 14, 2026.
