Ford Flags an Odd Defect Found in Only Two Vehicles Built This Year

Ford has issued a recall for just two vehicles — a Maverick pickup and an Escape crossover — after discovering that a supplier accidentally installed the wrong covers on their brake system control modules. Both vehicles were built in June 2025, and the issue surfaced during an internal quality check. While Ford has had a long list of recalls this year, nearly reaching 150 notices, this one stands out simply because it affects only two units, unlike recent large-scale campaigns involving 230,000 Bronco SUVs and nearly 21,000 Escape and Corsair models.

According to the official report, the affected vehicles were fitted with an electronic brake booster using an incorrect ECU cover. This mismatch can cause the control module to overheat, fail, and ultimately reduce brake pressure — a scenario that could compromise vehicle stability.

Ford notes that “if the electronic control module fails, drivers will see warning messages pop up on the instrument cluster.”

The company traced the problem back to the production stage: ECU covers were stored in mislabeled bins at Aumovio, a supplier in Mexico. A worker at Ford’s Flat Rock plant noticed something was off in September, prompting the issue to be escalated to the critical concerns review group. No crashes or injuries have been linked to the defect.

Owners of the two vehicles will receive recall notices between November 24 and 28. Dealers have been instructed to replace the entire electronic brake booster assembly on both units.

The incident underscores how fragile modern supply chains can be. Even a simple labeling mistake can introduce safety concerns. Ford’s quick response and tightly focused recall suggest improvements in quality-monitoring systems — though the company’s overall recall count remains high.