General Motors (GM) will be asking a small number of 2022 Chevrolet Heavy Duty (HD) truck owners to return to their GM dealership for a problem affecting the brakes in their vehicles. The primary hydraulic brake line assembly may have not been tightened to manufacturer specifications and could loosen and leak.

The vehicles affected by this problem include:

2022 Chevrolet 4500HD
2022 Chevrolet 5500HD
2022 Chevrolet 6500HD

In April 2022, during assembly end of the line testing, GM discovered that several of their Chevrolet HD trucks were experiencing a soft brake pedal feel and/or extended stopping distances. Navistar, the manufacturer of these vehicles informed GM that they intended to file a safety recall for this condition, and in May, GM’s Safety and Field Action Decision Authority (SFADA) decided to conduct a safety recall on the GM badged vehicles produced in the same suspect production period as the recalled Navistar vehicles. GM is not aware of any relevant field reports or crashes related to this problem.

According to the defect report, an investigation by the manufacturer of these vehicles found that the pressure sensor fitting of the primary hydraulic brake line assembly may not have been tightened to the correct manufacturer torque specification. If the brake line assembly loosens and brake fluid is lost, drivers may experience a soft or low brake pedal feel, extended stopping distances and the brake warning light may illuminate. Owners may also notice brake fluid on the ground or in the engine compartment.

Owners receiving notices will be asked to return to their dealers to have the brake pressure switch tightened to specification. They will also bleed the brake system and top off the brake fluid.

GM’s number for this recall is N222368230 and the NHTSA campaign number is 22V-364.

A small number of 2020-2021 Kia Rio vehicles may have been built with brake master cylinders that are not designed to manufacturer specifications. Kia will be contacting the owners of the affected vehicles starting January 11, 2022. The letter will have information describing the problem and how owners can get repairs done.

Kia first became aware of the defect in October 2021 when the supplier of the brake master cylinder notified them of a brake-related complaint in a Hyundai vehicle. Because this vehicle uses the same brake master cylinder as certain Kia Rio vehicles an investigation into the problem was opened for both Kia Rio and Hyundai Accent vehicles.

Based on a review of supplier quality control records and Kia’s vehicle production records, vehicles produced before 7/2/2021 could be equipped with improperly machined brake master cylinder bodies.

According to the defect report, the master cylinder body may have been machined with a sharp edge that could contact and damage the oil seal in the master cylinder. A damaged oil seal can impair vehicle braking functions, such that the driver may experience a hard or spongy brake feel, longer brake pedal travel, and extended stopping distances.

All owners of the affected vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Dealers will replace the brake master cylinder with a new one. Kia’s number for this recall SC223 and the NHTSA campaign number is 21V-936.

This problem also affects certain 2021 Hyundai Accent vehicles. The brake master cylinder may have been manufactured with sharp edges that can damage the inner oil seal and result in reduced braking performance. Hyundai’s recall number is 213 and the NHTSA campaign number is 21V-937.

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Ford Motor Company (Ford) is recalling certain 2021-2022 Bronco Sport and 2021-2022 Escape vehicles because they fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 135, “Light Vehicle Brake Systems.”

In October 2021, Ford was contacted by the NHTSA’s Office of Vehicle Safety Compliance regarding the results of a compliance audit on the 2021 Bronco Sport vehicle equipped with a brake vacuum booster. According to the defect report, the stopping distance test results for “Brake Power Assist Unit Inoperative” exceeded the federal regulation stopping distance of 168 m. Ford compared data from the NHTSA test vehicle to data from the Ford certification test vehicle and could not identify the difference in performance between the two test vehicles.

In November, Ford conducted further testing which included the “Brake Power Assist Unit Inoperative” portion, on a 2021 Bronco Sport equipped with a brake vacuum booster without a vacuum sensor, to replicate NHTSA’s test vehicle. The test vehicle was fitted with a new current batch of brake linings from the assembly plant and the stopping distance test results exceeded the federal requirements.

Analysis of the brake system identified that the friction coefficient of the rear brake caliper linings was below manufacturer specifications. Vehicles equipped with rear brake linings that have a friction coefficient that is outside of the specified tolerances would experience longer stopping distances if the vacuum sensor is not there to compensate for variations in brake pad friction performance.

The 2021-2022 Ford Escape shares the same brake system as the Bronco Sport and the same certification test applies to both vehicles. Some Bronco Sport and Escape vehicles are equipped with a brake vacuum booster and some are equipped with an Electronic Brake Booster (EBB). Vehicles with an EBB are not affected by this issue because they have higher system pressures if the booster malfunctions.

The remedy is currently under development. Ford’s number for this recall is 21C31 and the NHTSA campaign number is 21V-922.

A small number of 2021 Ford F-150 trucks could experience an electronic brake booster leak. The leak could result in brake fluid entering the electronic control unit (ECU), causing longer break pedal travel, higher pedal effort and reduced braking.

In May 2021, Ford’s Critical Concern Review Group reviewed three F-150 truck warranty claims where brake fluid from the electronic brake booster leaked into the ECU. Ford’s review of supplier records found that the supplier had identified 169 2021 model year F-150 brake booster assemblies in December 2020 because they were potentially assembled with a broken clinching tool, used to secure the pressure sensor to the booster housing. Further review of supplier and Ford records determined that 51 of the 169 quarantined parts were inadvertently shipped to Ford’s Dearborn Truck Plant and assembled into vehicles, all of which were shipped to dealers in the U.S.

Engineering analysis found that a brake booster with an incomplete clinch between the pressure sensor and the brake booster housing can cause brake fluid to leak through the pressure sensor into the ECU. This can reduce braking effectiveness of the brake circuits.

Those receiving notifications will be asked to return to their dealerships to have the ECU replaced. Ford’s number for this recall is 21S33 and the NHTSA campaign number is 21V-533.

A small number of 2020 Chevrolet Bolt EV owners will be returning to their dealerships to repair a problem affecting the brakes in their vehicles. General Motors has decided that this defect can affect vehicle safety.

According to the defect report, certain 2020 Chevy Bolt EVs may have improperly cast front left brake calipers. (Iron used to manufacture the caliper was not properly treated by the supplier prior to casting.) During a high pressure braking event, the caliper could fracture and brake fluid would be lost to half of the vehicle’s braking system. The problem could result in an unexpected reduction in brake performance and an increased chance of an accident.

Owners receiving notices will be asked to return to their dealerships to have the casting lot number of the front left brake caliper inspected and replace as necessary. GM’s number for this recall is N202321400 and the NHTSA campaign number is 20V-808.

Volkswagen will be contacting a small number of 2019 Volkswagen Arteon sedan owners, because of a manufacturing error affecting the braking system.

According to the defect report filed with the NHTSA, the electronic brake booster pressure input rod may have been incorrectly attached to the brake pedal. This incorrect installation may require the driver to use extra braking force and could lead to a disconnection of the pressure input rod. Additionally, in the event of a 12V power failure, the brake performance could be further impaired.

Volkswagen dealers will inspect the mounting of the pressure rod and replace the electronic brake booster and mounting of the pressure rod, depending on the inspection results. Volkswagen’s number for this recall is 47P8 and the NHTSA campaign number is 20V-135.

Click Here to view the complete 2019 Volkswagen Arteon recall notice.

Volkswagen will be contacting the owners of certain 2018 Atlas and 2017-2018 Passat vehicles, to notify them of a problem affecting the vehicles braking system. According to the defect report, the brake caliper carrier (bracket) bolts may have been torqued incorrectly, could loosen and cause the break caliper to move on the steering knuckle (Atlas front brake) or on the axle (Passat rear brake). If this happens, drivers may notice increased stopping distances and reduced vehicle control.

Dealers will inspect the brake caliper bracket bolt for tightness, replacing and re-torque the bolts as necessary. Additionally brake caliper fasteners, bleeder valve, and brake hose bolts will be checked and torqued to the correct specification, if necessary. For Passat vehicles, dealers will also inspect the parking brake cable for proper connection. Owners wanting more information about the problem are asked to contact Volkswagen customer service at 1-800-893-5298. Volkswagen’s number for this recall is 46H6 and the NHTSA campaign number is 18V-536.

General Motors will be contacting the owners of certain 2017 Cadillac XTSs and 2017 GMC Acadias regarding a problem affecting the brake system. An investigation into the subject vehicles found that the supplier of the brake caliper assembly may have incorrectly oversized the front caliper piston bore during machining. The oversized bore could prevent proper compression, allow the seal to extrude between the piston and the bore, and could result in a brake fluid leak. Drivers may experience reduced braking and/or an illuminated brake warning light.

Dealers will inspect the front brake calipers, replacing the assemblies as necessary. Owners wanting more information about the problem are asked to contact GM customer service at 1-800-458-8006 (Cadillac), or 1-800-462-8782 (GMC). GM’s number for this recall is 16096 and the NHTSA campaign number is 16V-8020.