Apprentice braking system mistakes can cause four-ton work trucks to be unroadworthy. Ford issued its 77th recall this year because someone forgot brake assembly 101. The company pulled 2,345 Super Duty trucks off the road with an urgent “Do Not Drive” warning after discovering a trainee operator skipped installing retaining springs that keep your brake pedal connected to the actual braking system.
Investigations traced the problem to an operator “new to the role and in training” who failed to install the retaining spring during assembly between March 19 and May 4, 2025. Camera verification systems used to catch errors were either down or producing unclear images during this period. The combination created a perfect storm of manufacturing oversight that reached customer driveways.
Affected trucks span the entire Super Duty range with F-250 (1,304 units), F-350 (807 units), F-450 (132 units), and F-550 (102 units) models all built at Ford’s Kentucky Truck Plant. That tiny missing spring means your brake pedal can swing freely during operation. No warning signs appear before total brake failure in a vehicle weighing over 8,000 pounds and capable of towing 40,000 more.
Discovery came during pre-delivery inspections when technicians found brake pedals “swinging freely” during parking lot test drives. Ford has confirmed three field reports and one warranty claim related to the defect. No accidents or injuries have occurred as of early June, thanks to the early detection during dealer inspections.
Quality control struggles at Ford have reached epic proportions this year. The automaker has issued more than 70 recalls in 2025, suggesting systematic manufacturing issues that extend beyond one trainee’s mistakes. Camera verification systems failing to verify critical safety components indicate deeper operational problems requiring immediate attention.
Response measures include free towing to dealerships and mobile repair teams for on-site inspections. Owner notification letters were mailed between June 18-23, 2025, with repairs typically taking under an hour once the missing spring is confirmed and installed. Ford covers all associated costs including rental vehicles during repair periods.
Verification of your truck’s recall status should happen immediately if you own a 2025 Super Duty. Check your VIN through Ford’s recall website or call 1-866-436-7332 for immediate confirmation. These trucks earned their reputation through decades of reliable work performance, not through gambling with brake system integrity during critical hauling operations.
