Flexible brake line ruptured and caused catastrophic loss of brakes (thurs, Mar 18, 2021). Second time this happened - first time was about 15-18 months ago - also reported. Both times vehicle taken to mac haik Ford dealership in houston, tx for service. (both times failed while in fast food waiting line).

- Houston, TX, USA

While pulling out of a parking space (less than 5 mph) I heard a clank/pop sound. When I then applied my brakes they sunk to the floor and barely stopped the car. I had no brakes. Brake fluid then started to puddle under the front passengers side wheel and on inspection I noticed the brake fluid dripping from the brake line. I have been current with all my car maintenance and there was never a mention of any issue with the break lines. I had this car towed and upon inspection by a mechanic it was determined that the front drivers side brake lines were also bulging and needed replacing. The front brake lines going from the caliper to the main brake line fitting, are the parts that were bad. I have attached pictures and notes from the mechanic. I have a link I can share as well as an invoice if needed. I did not share currently since it states not to put personal information on here.

- Woodbury, MN, USA

Traveling on highway at 70 mph with sudden immediate inability to maintain speed (loss of power/acceleration). Vehicle not responsive to acceleration request until below 45 mph and behaves erratically (just stops responding and car slows). No check engine light and car otherwise runs normally. Accompanying behaviors: Brake lights are constantly illuminated (stuck on), even when not braking and also when car is turned off and key removed. Intermittently when car is stopped, message "hill start assist not available" is shown. Took car into Ford dealership who diagnosed the problem and "found brake switch engagement bushing missing from brake pedal" and offered to replace the "brake pedal assembly" at a cost of $1,062.35. Found several forums complaining of the same exact behaviors and noting that the oem "brake pedal stop pad" had broken into pieces. I also remembered vacuuming up some plastic pieces from the driver front floor area not realizing where they had come from. The "brake pedal stop pad" itself which would cost less than $5 is not offered by Ford, so people are finding alternatives which may be unsafe and include: "brake pedal stop pad" not designed specifically for this vehicle, zip ties, and even magnets! other Ford models are affected as well. Some example forum links below. This should be a recall. Https://www.carcomplaints.com/Ford/mustang/2015/brakes/service_brakes.shtml https://www.mustang6G.com/forums/threads/brake-light-switch-near-pedal-failure.122100/

- Cypress, TX, USA

I was in the drive thru of a fast food restaurant. When I went to press on the brake pedal, it had no pressure behind it, and I was just barely able to stop the car. I was able to get the car into a nearby parking lot. I was just barely able to stop the car using the emergency brake. My car then showed a low brake fluid warning on the dash. So I opened the hood and saw that the brake fluid reservoir was completely empty. I had a family member come pick me up and drive me home. I later came back with a bottle of brake fluid so that I could try and find the leak. I discovered that the drivers side front brake line has been blown open, and was leaking brake fluid at a substantial rate. My car is still sitting in this parking lot, and I am currently making plans to have it towed to a mechanic.

- Kingwood, TX, USA

In June 2020, while driving and braking for stop signs and traffic lights, brake pedal started to get a little mushy, then the next time I stepped on brake I heard/felt a "pop" and brakes were failing and brake fluid light came on. I pulled off and a mechanic saw that the left brake line was broken, unsafe to drive and would need replacing. Today Aug 19, 2020, as I was stepping on brake to shift into gear, I heard that same "pop", my brake pedal went down very fast. I inspected car and found brake fluid sprayed all over right front wheel well and brake line was broken, making it unsafe to drive. I am very thankful this did not happen yesterday while driving on freeway and all over city streets and up and down hills. I have repair invoices for both occurrences in June and Aug, but am unable to scan and attach at this time.

- Alabaster, AL, USA

The contact owns a 2015 Ford Fusion. The contact stated that while attempting to place the vehicle in park, the brake pedal was depressed and the brake hose fractured which caused brake fluid to leak from the vehicle. The following day the contact stated she attempted to pour additional fluid in the reservoir however, she was unable to restart the vehicle. The vehicle made an abnormal noise and was unable to be driven. The vehicle was towed to fair oaks Ford Lincoln (2055 w. ogden ave, naperville, il 60540). The diagnosis was a right front brake hose rupture. The manufacturer was made aware of the failure and offered no assistance. The failure mileage was 32,000. The manufacturer offered a discount on the repair but said that the repair was not covered under the extended warranty.

- Naperville, IL, USA

The brake hose ruptured while parked.

- Mattapoisett, MA, USA

Heard a pop when I pressed on the brake pedal when I was stopped. Broke the brake line. Brake fluid leaked out everywhere and eventually lost all use of the brakes. The shop said that that the rubber hose on both sides were swollen. The passenger side was weak and broke.

- Kansas City, MO, USA

2015 Ford Fusion regularly serviced automobile with ~55K miles suffered a complete brake failure from a ruptured brake line. Auto repair shop indicates driver side line about to rupture (bubbling) as well. Phoned inquiry into Ford hq, no recall on record so they will not pay for any of estimated $850 repair. Ford case # [xxx]. vehicle was parked and stationary. Turned on car as normal, turned off electronic parking brake, backed up and started driving on a relatively flat and straight 25 mph city street about to enter highway 17 over santa cruz mountains. Pulled over when brake pedal moved all the way down to the floor with near zero braking ability. Car warning system did flash low brake fluid sign. Attached photo from repair shop shows complete brake line failure. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Los Altos, CA, USA

The car was parked in a lot. I started it, put it in reverse, and the check brake system warning message came up. The brakes made a loud metallic screeching sound when I began backing. When I tried to apply the brake, it was sluggish and difficult to stop the vehicle. I had it towed to a nearby Ford dealership, where they replaced a brake switch. Nine days later, the exact same thing happened, this time at my home. The car was towed to my mechanic (not the Ford house), who found a code in history indicating that the problem had a technician notice that states to replace power brake booster. He could not make the car duplicate the issue after clearing the codes, so I chose not to replace it. This part and repair will be over $800! when my mechanic called the Ford house to find the code they used to determine that a brake switch was out, he was told they did not make a note of the code. My mechanic went on to tell me that I should still have brakes if this happens again, but they will not be assisted by the booster and will require longer distances to stop. Since there is a technician's safety alert already posted, this has to have occurred on other vehicles, so there should be a safety recall to replace this booster. Ford did change the booster used the year after my vehicle was manufactured. I also wonder if the Ford house replaced a brake switch that was actually functioning properly when they needed to replace the booster. Since we have no code to refer to, we will never know.

- Denver City, TX, USA

Traveling in traffic around 25 mph with traffic slowing to a stop the brake pedal went soft and was pressed to the floor with almost no braking at all. This resulted in a rear end collision.

- Jupiter, FL, USA

The contact owns a 2015 Ford Fusion. The contact stated that the vehicle exhibited multiple failures. The vehicle lost power independently and the brake pedal failed to engage while driving. Also, after fueling the vehicle, the engine failed to start. Furthermore, when the accelerator pedal was depressed, the vehicle would not accelerate. The vehicle was taken to elk grove Ford (9645 auto center drive, elk grove, ca 95757, (916) 478-7000) where it was determined that the windshield wiper fluid penetrated the brake fluid. The brake lines, calipers, and the battery were replaced twice; however, the repairs did not correct the failures and the vehicle continued to stall. The vehicle was taken back to the dealer, but they could not duplicate the failures. The manufacturer was not contacted. The vehicle was not repaired. The failure mileage was not available.

- Elk Grove, CA, USA

The contact owns a 2015 Ford Fusion. While driving 25 mph, the driver's side brake line malfunctioned. The brake pedal was very loose and traveled to the floorboard. The contact was able to pull into a parking lot and bump against a curb to stop the vehicle. The vehicle was towed to an independent mechanic who repaired the driver's side brake line that was leaking brake fluid. The failure recurred with the passenger side brake line, which was also repaired by the same mechanic. In addition, the check engine indicator illuminated. The mechanic changed a coil pack on cylinder number four on the engine, but the failure recurred the following. The contact stated that the engine shook and excessive smoke poured out of the exhaust pipe. The vehicle was taken to riverside Ford (2089 riverside dr, macon, ga 31204, (478) 464-2900) where they changed a spark plug on cylinder number four. The failure recurred and the vehicle was taken back to the dealer. The dealer found coolant in the engine with the fluid entering through the cylinder number four block. The dealer quoted the cost to replace the entire engine. The manufacturer stated that the vehicle was not under warranty. The contact researched the failure and found that it occurred many times with a possible engine design crack. The manufacturer did not assist and referred the contact to NHTSA. The brake failures were repaired. The failure mileage was 86,000.

- Macon, GA, USA

The contact owns a 2015 Ford Fusion. While the contact was at a drive thru, the brakes went out and did not stop the vehicle. The contact used the emergency brake to stop the vehicle. There was no warning indicator illuminated. The vehicle was towed to mac haik Ford (713-932-5000, located at 10333 katy fwy, houston, tx 77024) where it was diagnosed that there was a failure in the front brake line. The vehicle was left at the dealer for repairs. The manufacturer was made aware of the failure. The failure mileage was approximately 49,800.

- Houston, TX, USA

Actually this happened to me twice. I was parked and when I touched the brakes to go into reverse but they went all the way to the floor. I called aaa to tow my vehicle. The 2nd time it happened I was 5 min from my house. Again I was parked at the kids game and when I pressed the brakes it made me think about the 1st experience. However it had a little pressure behind the brakes and I was able to pump my brakes to engage them thereby making it home. A friend came over added brake fluid and I was surprised that it was taking all the fluid. To my surprise all of the brake fluid was coming out on the ground. Both times the dealer claimed they were not aware of an issue with the brakes and am responsible for the cost of the repairs if it's not covered under warranty.

- Florissant, MO, USA

Antilock brake vacuum pump failed while driving on city street at 40-45 mph. Almost caused serious accident. Brake pump failure caused camshaft failure and a bearing to fall apart and put metal shavings into engine. Now engine, per dealership, will need to be replaced.

- Grand Prairie, TX, USA

On Wednesday July 3, 2019, I noticed when I got into my car in the morning that my brake pedal seemed soft and I had to push it almost all the way to the floor to make my brakes work. I left for a trip that afternoon driving approximately 160 miles on the highway, and the brake softness remained the same for the next few days. However, on the trip back on 7/7/2019, when sitting in a drive-thru, my brake light came on the dash and a warning about my brake fluid being low came on the screen. I had virtually no brake power, and even when I pushed the pedal to the floor my car was still creeping forward. I managed to drive to an auto parts store where I purchased some brake fluid. This made the warning go away, but the brakes were still barely functional. I made it home, and noticed fluid leaking from the bottom of my car and all over the front passenger wheel. I took the car to a repair shop the next day (7/8/2019) where they found that one brake line had burst on the front passenger wheel, and the brake line on the front driver's wheel was about to burst. Both brake lines had to be replaced.

- Greendale, WI, USA

I was parked with my vehicle off. When I turned on my vehicle and put it in reverse to back out of my parking spot I heard a small pop and the brake pedal had a lot more "give" to it. I was able to push it all the way to the floor. While driving, I had to push it to the floor to slow my vehicle. I was able to safely make it to my mechanic who luckily was only 1 mile away. He told me the front right brake line was ruptured and that this is almost unheard of in a car that's only 4 years old.

- Inverness, IL, USA

While my wife was in a drive thru moving forward slowly she reported that the rake pedal depressed all of the way to the floor and had a hard time stopping the car. Wife inspected brake fluid reservoir and found it to be completely bone dry. Dealership found the right front brake line to have failed causing all of the fluid to leak out and the brakes to fail. Dealership advised that the part is on back order and does not know when it will be available leaving me assed out. Also this part is not covered under our extended premium Ford warranty. I have researched different online forums and have found multiple people with the exact same problems with some that were traveling at a much higher rates of speed. I think this needs to be investigated before a serious accident occurs.

- Flint, TX, USA

Ford Fusion hybrid, stationary(parked on a slightly raised drive way) for 2 weeks I was on vacation. The car was parked with the gear shifter in parking. Neighbor told me brake lights came on all of a sudden. Stayed on for 3 days, and went out. Car needed jump start. Car is at Ford dealership in sarasota fl. I was told the switch on the back of the brake pedal is broken. Car needs brake pedal assembly replaced.this rare part is on national back order. My car has 64000 miles on it.car has been grounded for 3 weeks already. Car has been grounded for 3 weeks already. Could this be a safety risk?

- Sarasota, FL, USA