Four problems related to brake light on have been reported for the 2016 Ford Expedition. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2016 Ford Expedition based on all problems reported for the 2016 Expedition.
While driving the vehicle at approx 35 mph on a city street. The brakes were lightly applied upon approaching a traffic light. The pedal, without any warning, went straight to the floor with no resistance and then the brake warning light came on. Pumping the brakes allowed the vehicle to slowly decelerate but, pedal travel consistently went full throw. A visual inspection showed an empty fluid reservoir and no indication of an external leak. The break down shows the master cylinder failed and was diverting the brake fluid into the boost assembly. The vehicle has 56,511 miles on it.
I was driving and my low brake fluid light came on and my brake pedal went to the floor. Took it to my mechanic and my master cylinder is cracked.
I was traveling away from home and was towing my boat (about 4k weight). No performance issues or warning lights on the trip thus far. When leaving the hotel we stayed in, I pressed the brake to put the truck in gear. The brake pedal went straight to the floor. All the way down. The low brake fluid light came on and the brake warning light was illuminated too. The fluid reservoir, topped off a week before, was completely empty, yet no fluid was on the ground. Got the truck towed to a Ford dealer. Needed a new master cylinder and brake booster, saying that the seal between those 2 parts failed and the fluid quickly transferred from the previously sealed master cylinder into the brake booster. Doing a bit of research, I see a NHTSA recall on f-150s that have the same master cylinder and booster. I also see an investigation underway for '15 and '16 f150s for brake failure. And I see story upon story of Expedition owners on the Expedition forum describing the same critical, potentially catastrophic failure. I'm grateful the truck was stopped when it failed. I truly feel I would not be here describing the situation to you if it had failed on the highway, on a boat ramp, or even in a city. It's remarkable to me that possibly a $2. 00 seal (part) could have cost me my life, or those also in the truck. It's unacceptable to allow trucks to remain on the road with a cheap part that can fail that easily, likely causing death or significant injury to self and those you run into. Ford can do better. Nhtsa can do better. Let's get this recalled before others die unnecessarily.
The check brake light turned on. The brake fluid reservoir was empty. Refilled and drained immediately with no visible leaks from system. Pedal could be pressed to floor without activating brakes. Mechanic determined that master cylinder was defective and leaking into booster.