2008 FORD FUSION

6 recalls, 1,532 complaints - 43 TSBs

AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

Defect Description

Ford Motor Company (Ford) is recalling certain 2007-2011 Ranger, 2006-2012 Fusion, Lincoln Zephyr, Lincoln MKZ, 2006-2011 Mercury Milan, 2007-2010 Ford Edge, and Lincoln MKX vehicles. The driver's side air bag inflator may explode due to propellant degradation occurring after long-term exposure to ... Read more

Consequence

An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.

Remedy

Ford will notify owners, and dealers will replace the driver-side airbag inflator or module with an alternate one, free of charge. Owner notification letters were mailed on April 9, 2021 for the passenger side, and November 14, 2022 for the driver side. Owners may contact Ford customer service at ... Read more

2,602,668 vehicles affected

Manufacturer: Ford Motor Company

AIR BAGS:FRONTAL

Defect Description

Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as... Read more

Consequence

In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.

Remedy

Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S... Read more

1,067 vehicles affected

Manufacturer: Ford Motor Company

SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:CONTROL UNIT/MODULE

Defect Description

Ford Motor Company (Ford) is recalling certain 2006-2010 Ford Fusion, Mercury Milan, Lincoln Zephyr and MKZ vehicles. The valves within the ABS Hydraulic Control Units (HCU) may react with brake fluids containing specific corrosion preventative additives. This reaction may cause the valves to not ... Read more

Consequence

If the valves do not properly close, additional brake pedal travel may be required to stop the vehicle, increasing the risk of a crash.

Remedy

Ford will notify owners, and dealers will flush the brake system with DOT 4 fluid and install a new brake fluid reservoir cap. In addition, the HCU will be tested to detect a possible stuck valve condition, replacing the HCU as necessary. All services will be performed free of charge. The recall ... Read more

600,166 vehicles affected

Manufacturer: Ford Motor Company

AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Defect Description

Ford Motor Company (Ford) is recalling certain 2012 Ford Fusion and Mustang and Lincoln Zephyr and MKZ vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Marian... Read more

Consequence

An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.

Remedy

Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Interim letters informing owners of the recall and that parts are not yet available began mailing March 1, 2... Read more

654,695 vehicles affected

Manufacturer: Ford Motor Company

AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Defect Description

Ford Motor Company (Ford) is recalling certain model year 2007-2011 Ford Ranger vehicles, 2006-2011 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2007-2010 Ford Edge, Lincoln MKX vehicles, 2005-2006 Ford GT vehicles, and 2005-2011 Ford Mustang vehicles originally sold, or ever register... Read more

Consequence

An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.

Remedy

Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Ford mailed interim letters informing owners that parts are not yet available on July 15, 2016. Owners will... Read more

1,892,343 vehicles affected

Manufacturer: Ford Motor Company

EQUIPMENT

Defect Description

Ford Motor Company (Ford) is recalling certain all weather driver side accessory floor mats sold for use in model year 2006-2011 Ford Fusion and Mercury Milan, 2006 Lincoln Zephyr, and 2007-2011 Lincoln MKZ vehicles manufactured November 9, 2007, through October 31, 2010. The affected floor mats ma... Read more

Consequence

The floor mat could shift such that it could interfere with the accelerator pedal, preventing its return to an idle position, which could result in unintended vehicle speeds, increasing the risk of a crash.

Remedy

Ford will notify owners, and dealers will install new replacement mats, free of charge. The recall began in July 2014. Owners may contact Ford's customer service at 1-800-392-3673. Ford's number for this recall is 14S07. NOTE: Vehicles built after October 31, 2010, while potentially equipped wit... Read more

82,579 vehicles affected

Manufacturer: Ford Motor Company

Complaint Statistics

1,532 total complaints 68 crashes 6 fires 38 injuries

Top Reported Components

Component	Complaints
AIR BAGS	638
SERVICE BRAKES	472
SERVICE BRAKES, HYDRAULIC	66
POWER TRAIN	45
ENGINE	42
UNKNOWN OR OTHER	37
STRUCTURE	35
STRUCTURE:BODY	32
ELECTRICAL SYSTEM	30
VEHICLE SPEED CONTROL	22

Incident date: Aug 30, 2025

Steering asst warning came on. This happened in 2022 when I got the vehicle and it’s now happening again. When stopped with foot on brake and auto stop engaged , you take foot off brake steering wheel jerks and steering asst warning comes on. There is also a problem with shift to park. Vehicle sh... Read more

Incident date: Jun 3, 2019

This is the second time the driver seatbelt has locked itself and won't extend. The fix is to remove the seatbelt and send it in for repair. This seems serious as it forces me to drive without a seatbelt.

Incident date: Jan 1, 2024

Sometimes when I drive it will say my forward collision is blocked so it will disable but it normally shuts off. Tonight I'm driving on the freeway a steering wheel pops up then blind spot abs traction and a few more lights come on then it say check headlights those are dimming the radio is cutting ... Read more

Incident date: Sep 11, 2024

The contact’s son owns a 2015 BMW 328I. The contact received notification of NHTSA Campaign Number: 24V608000 (Engine and Engine Cooling, Electrical System). The contact stated that while his son was driving approximately 45 MPH, the vehicle stalled. The vehicle was not able to be restarted. The v... Read more

Incident date: Oct 7, 2024

On 10/14/2024, My vehicle got broken into and my gun, magazines, and gun case got stolen. The vehicle alarm system did not go off. This is a safety issue, in addition, it is a manufacturer defect.

Incident date: Jun 3, 2019

When approaching 60 mph the vehicle starts to vibrate / shake. Upon a dealer's recommendation they have rotated, aligned, balanced and changed the tires and repaired the rear rims, but they did not help. (Just cost us money). I contacted Hyundai and they suggested that I go to another dealer, whic... Read more

Incident date: Aug 15, 2024

Plexiglass window on house door to RV separates. This is a known issue to Winnebago which has provided warranty coverage for up to three years, even though the problem typically manifests at or after three years. The window separates from the house door either partially or completely - in the latt... Read more

Incident date: Feb 27, 2024

Error code P052E Positive crankcase ventilation regulator valve performance

Incident date: Feb 27, 2024

Car was involved in a head on collision [XXX] with a concrete exit barrier after being pushed into the lane by a driver trying to in front of them trying to make a last second dash for the exit. Not sure if the driver was in blind spot, but the vehicle trying to merge did use turn signal or respond... Read more

Crash 1 injured

Incident date: Feb 27, 2024

I bought this car and the light bulb is replaced. It is the actual halo type plastic head lights that are defected. If I take to dealer can they fix it. I saw issues with the same thing on the Internet.

Incident date: Oct 1, 2023

The heater on the car didn't work, It turns out the coolant was leaking that led to the water pump issue. Things started to fail on the vehicle and lights came on. It left me stranded on the highway. The car shut down on the Intestate. That was so dangerous and scary, too. Took the car to Ford for... Read more

Incident date: Jan 16, 2024

Smell of gas

Incident date: Aug 14, 2023

The contact owns a 2012 Ford Fusion. The contact stated that while driving at an undisclosed speed, the vehicle experienced a loss of power steering assist. The "Service Power Steering" message was displayed. The contact coasted into a gas station and parked the vehicle. The vehicle was towed to the... Read more

Incident date: Aug 14, 2023

The contact owns a 2016 Ford Focus. The contact stated that while driving at an undisclosed speed, the check oil warning light illuminated, and the vehicle lost motive power. The vehicle was towed to an independent mechanic, who diagnosed a failure with the timing chain. The vehicle was not repaired... Read more

Incident date: Jun 28, 2023

A few months ago, car started alarming randomly. Upon entering vehicle all lights on dashboard were going on and off, screen was going through each system followed by "problem" and repeated clicking heard in steering column and captured on video for 1 minute. This continued for several days but car ... Read more

Incident date: Jun 28, 2023

Main HV Battery failure, "Electrical System Error" displayed, fortunately this occurred when pulling into the garage. Vehicle would not go into drive or reverse, vehicle had to be towed to the dealership. This could have ended very differently if on the highway. HV Battery Module and 12v batter... Read more

Incident date: Jun 10, 2023

The contact owns a 2016 Ford Fusion. The contact stated that while his wife was driving at an undisclosed speed, the vehicle was jerking uncontrollably. No warning lights were illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the clutch. The vehicle was not repaired. Aft... Read more

Incident date: Jun 10, 2023

The contact owns a 2023 Kia Niro. The contact stated that while attempting to shift into drive (D), the transmission failed to shift to the intended gear. The contact stated that the failure was intermittent. The vehicle was taken to the dealer; however, the dealer was unable to duplicate the failur... Read more

Incident date: Dec 17, 2022

Truck was repaired June 2019. They welded the jam nut which made it impossible to get an alaignment.Been having a open claim with Chrysler Jeep and Dodge going on 2 years per claim #78469040 Front Suspension Track Bar Frame Bracket ( vehicle recently started to do the death wobble again)

Incident date: Dec 17, 2022

The contact owns a 2018 Nissan Rogue. The contact stated that the front driver's and passenger's side seat belts failed to chime when the seat belt was unfastened while driving. The seat belt warning light was illuminated. The dealer was made aware of the failure; however, the vehicle was not diagno... Read more

Incident date: Mar 11, 2023

Brake actuator is not working properly and will eventually get us in an accident. We bought the car brand new. There is a recall for this issue, but we were never notified by Toyota. After contacting Toyota, they claim we are out of the recall dates and will do nothing. I have requested a copy of th... Read more

Incident date: Aug 8, 2022

I bought this Tesla model y in less than a month to be specific February 23th, I was forced to park the car due to rear motor failure. I had barely any time to find a parking lot before the car shot down on me. Until today, I have not gotten the car yet from Tesla due to long delay repair time.

Incident date: Feb 28, 2023

The contact owns a 2007 Chevrolet Avalanche. The contact stated that while driving at various speeds, the vehicle stalled. The check engine warning light was illuminated and a message indicating that the vehicle was in Reduced Power Engine mode was displayed. The contact veered to the side of the ro... Read more

Incident date: Dec 18, 2019

The contact owns a 2018 Subaru Impreza. The contact received notification of NHTSA Campaign Number: 22V624000 (Exterior Lighting) however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable am... Read more

Incident date: Jan 9, 2023

Service power steering in 2011 Ford fusion SE 2.5 L

Incident date: Jan 9, 2023

Service power steering in 2011 Ford fusion SE 2.5 L

Incident date: Dec 11, 2022

The contact owns a 2008 Ford Fusion. The contact stated while driving at an undisclosed speed, the vehicle drove over a bump in the roadway and the contact depressed the brake pedal however, the vehicle failed to stop immediately. The contact depressed the brake pedal to the floorboard, and the vehi... Read more

Incident date: Dec 28, 2022

The contact owns a 2008 Ford Fusion. The contact stated while driving 20 MPH and driving over a black ice, the contact felt the brake pedal had lost pressure. The contact desperately pushed on the brake pedal for the vehicle to stop. The vehicle was taken the dealer and the contact was informed that... Read more

Incident date: Mar 25, 2021

Takata recall. The contact owns a 2008 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The... Read more

Incident date: Mar 25, 2018

The contact owns a 2008 Ford Fusion. The contact stated while driving at various speeds and depressing the brake pedal, the brake pedal went down to the floorboard. There was no warning light illuminated. The contact received notification of NHTSA Campaign Number: 19V904000 (Service Brakes, Hydrauli... Read more

Incident date: Oct 6, 2022

The contact owned a 2008 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) and would like to be removed from the recall distribution list as the vehicle had been totaled. The local dealer was not contacted. The manufacturer was contacted.

Incident date: Jul 25, 2022

The contact owns a 2008 Ford Fusion. The contact stated that while the car was parked outside in the sun, the passenger’s side dashboard nearby the air bag became deformed. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified. The approxi... Read more

Incident date: Jul 25, 2022

Incident date: Jun 17, 2022

My Breaks gave way for some odd reason I ran into a cable box trying to control or rather stop the vehicle.

Crash

Incident date: Jun 17, 2022

My Breaks gave way for some odd reason I ran into a cable box trying to control or rather stop the vehicle.

Crash

Incident date: Jun 17, 2022

My Breaks gave way for some odd reason I ran into a cable box trying to control or rather stop the vehicle.

Crash

Incident date: Jun 8, 2020

The contact owns a 2008 Ford Fusion. The contact stated while driving at various speeds, the brake pedal was depressed but went all the way to the floorboard and the vehicle hesitated to respond, causing a stopping distance delay. There was no warning light illuminated. The contact received notifica... Read more

Incident date: Jun 8, 2020

Incident date: Aug 15, 2021

The contact owns a 2008 Ford Fusion. The contact stated while driving approximately 25 MPH, the vehicle stalled. There were no warning lights illuminated. The vehicle was taken to a local dealer and diagnosed the vehicle with #4-cylinder failure. The contact purchased the parts and had an independen... Read more

Incident date: Apr 1, 2022

The contact owns a 2008 Ford Fusion. The contact stated while sitting in the vehicle there was an abnormally loud popping sound before the brake pedal went to the floorboard. The ABS and check engine warning lights were illuminated. The vehicle was not diagnosed or repaired. The manufacturer had not... Read more

Incident date: Apr 1, 2022

Incident date: Jun 2, 2020

The contact owns a 2008 Ford Fusion. The contact stated while driving at an undisclosed speed, the contact depressed on the brake pedal however, the vehicle failed to stop in a reasonable time. The contact depressed the brake pedal all the way to the floorboard for the vehicle to stop. The contact s... Read more

Incident date: Jun 2, 2020

Incident date: Jan 8, 2020

The contact owns a 2008 Ford Fusion. The contact received a recall notification for NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic) however, the dealer informed the contact that the parts for the recall repair were not yet available. The contact stated that while driving at various spee... Read more

Incident date: Jan 18, 2022

Unknown

Incident date: Jan 13, 2021

The number 16 transmission fuse would blow and then the car wouldn’t start until you replaced the fuse and now it’s not even starting when the fuse is replaced.

Incident date: Jan 5, 2022

The contact owns a 2008 Ford Fusion. The contact stated that while driving in the snow, the ABS engaged, and the brake pedal depressed to the floorboard without warning. Additionally, the contact stated that the failure might last for a few seconds or for a few days. The contact received notificatio... Read more

Incident date: Jan 5, 2022

Incident date: May 17, 2021

I am unable to safely brake. When I press my foot on the brake, it doesn’t engage until it completely touches the floor of the car.

Showing 50 of 1,532 complaints.

EPA Fuel Economy, 2008 FORD FUSION

Trim / Engine	City MPG	Highway MPG	Combined MPG	Fuel Type	Annual Fuel Cost
2.3L 4-cyl, Automatic 5-spd (Front-Wheel Drive)	20.0	28.0	23.0	Regular	$2,700
2.3L 4-cyl, Manual 5-spd (Front-Wheel Drive)	20.0	29.0	23.0	Regular	$2,700
3.0L 6-cyl, Automatic 6-spd (Front-Wheel Drive)	18.0	26.0	21.0	Regular	$2,950

CO2 Emissions: -1.0 g/mile (Midsize Cars)

Source: U.S. Environmental Protection Agency (EPA). Actual fuel economy may vary based on driving conditions.

Technical Service Bulletins, 2008 FORD FUSION

43 manufacturer communications from 17 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
140000 AIR BAGS	5
350000 EQUIPMENT	5
060000 ENGINE AND ENGINE COOLING	2
061000 ENGINE AND ENGINE COOLING:ENGINE	2
353000 EQUIPMENT:ELECTRICAL	2
030000 BRAKES (PWS)	2
060000 ENGINE (PWS)	2
030000 SERVICE BRAKES, HYDRAULIC	1

350000 EQUIPMENT

All accessory stick-on keyless entry keypads come with a wallet card containing the master code. If the accessory keypad was factory installed, this card will be placed in the glove box and should be handed to the vehicles owner during ini

060000 ENGINE AND ENGINE COOLING

When performing any transmission fluid change or topoff involving MotorcraftA? Premium ATF, MERCONA? V has replaced all versions of MotorcraftA? Premium ATF and can be used going forward. Mixing MotorcraftA? Premium ATF and MERCONA? V in th

140000 AIR BAGS

Certain 2005-2014 Mustang, 2005-2006 GT, 2004-2011 Ranger, 2006-2012 Fusion and MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge & MKX Vehicles Driver & Passenger Airbag Module Quality Control Inspection REASON FOR THIS SUPPLEMENT ??A?A?

140000 AIR BAGS

Certain 2005-2014 Mustang, 2005-2006 GT, 2004-2011 Ranger, 2006-2012 Fusion & MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge & MKX Vehicles Driver & Passenger Airbag Module Quality Control Inspection: Ford Motor Company has determined that

030000 SERVICE BRAKES, HYDRAULIC

Certain 2006-2010 Model Year Fusion/Milan/MKZ/Zephyr Vehicles Equipped with Anti-Lock Brake Systems DOT 3 Brake Fluid and Anti-Lock Brake System Function In some of the affected vehicles, customers may return to the dealer with complaints

350000 EQUIPMENT

Replacing the original equipment SYNC/Navigation system with either an aftermarket SYNC/Navigation kit or modifying original SYNC/Navigation parts to provide additional features is not recommended nor supported on any Ford, Mercury or Linco

353000 EQUIPMENT:ELECTRICAL

The Accessory (Wireless) Keyless Entry Keypad can only be used with vehicles that are factory built with Remote Keyless Entry (RKE). The master code for the Accessory (Wireless) Keyless Entry Keypad can be retrieved from FMCDealer - Parts a

350000 EQUIPMENT

353000 EQUIPMENT:ELECTRICAL

140000 AIR BAGS

Certain 2006-2008 Model Year Fusion and Milan, 2006 Zephyr, 2007-2008 MKZ and 2007-2008 Edge, MKX and Ranger Vehicles - Driver Airbag Inflator Replacement

140000 AIR BAGS

Certain 2006-2008 Model Year Fusion and Milan, 2006 Zephyr, 2007-2008 MKZ and 2007-2008 Edge, MKX and Ranger Vehicles - Driver Airbag Inflator Replacement

140000 AIR BAGS

Certain 2006-2008 Model Year Fusion and Milan, 2006 Zephyr, 2007-2008 MKZ and 2007-2008 Edge, MKX and Ranger Vehicles - Driver Airbag Inflator Replacement

350000 EQUIPMENT

REPLACING THE ORIGINAL EQUIPMENT SYNC/NAVIGATION SYSTEM WITH EITHER AN AFTERMARKET SYNC/NAVIGATION KIT OR MODIFYING ORIGINAL SYNC/NAVIGATION PARTS TO PROVIDE ADDITIONAL FEATURES IS NOT RECOMMENDED NOR SUPPORTED ON ANY FORD, MERCURY OR LINCO

030000 BRAKES (PWS)

SOME 2008-2017 FORD/MERCURY/LINCOLN VEHICLES EQUIPPED WITH SYNC MAY GENERATE A VHR THAT IDENTIFIES A CONCERN WITH THE BRAKES AND SUSPENSION CATEGORY INDICATING SERVICE IS REQUIRED DUE TO A BRAKE SYSTEM WARNING LAMP BEING ILLUMINATED. IF THE

030000 BRAKES (PWS)

062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate

060000 ENGINE (PWS)

063200 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

063140 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR

063130 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)

063110 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CRANKCASE (PCV)

063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

062200 ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

060000 ENGINE AND ENGINE COOLING

061000 ENGINE AND ENGINE COOLING:ENGINE

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

061110 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS

061120 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER

061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL

061320 ENGINE AND ENGINE COOLING:ENGINE:OTHER FUEL TYPES:TURBO/SUPERCHARGER

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

062300 ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS

350000 EQUIPMENT

FORD: A JOB AID WAS DEVELOPED AND NOW AVAILABLE FOR THE PTU INTERNAL OR EXTERNAL FLUID LEAKAGE FOR ALL WHEEL DRIVE VEHICLES. *PE

103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)

FORD/LINCOLN/MERCURY: SOME VEHICLES, WITH DIAGNOSTIC CODES (DTCS) P0351, P0352, P0353, P0354, P0355, MAY EXPERIENCE A MALFUNCTION INDICATOR LAMP IN THE POWERTRAIN CONTROL MODULE (PCM) AND ONE OR MORE COIL ON PLUG(S) DAMAGE. MODELS 2006-08

060000 ENGINE (PWS)

FORD/LINCOLN/MERCURY: MAY HAVE SLUDGE BUILDUP IN THROTTLE BODY LEADING TO LESS AIRFLOW OR ENGINE IDLING RPM FLUCTUATION AND HARD STARTS OR BATTERY DISCONNECT OR DEAD BATTERY AFTER KEEP ALIVE MEMORY (KAM) CLEAR. MODELS 2003-05 THUNDERBIRD

111000 ELECTRICAL SYSTEM:12V/24V/48V BATTERY

118000 ELECTRICAL SYSTEM:SOFTWARE

FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION. *RM

100000 POWER TRAIN

FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION. *RM

061000 ENGINE AND ENGINE COOLING:ENGINE

FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION. *RM

046000 SERVICE BRAKES, AIR:ANTILOCK

FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION. *RM

015200 STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS

POWER STEERING FLUID LEAKS FROM STEERING RACK AND PUMP ATTACHMENT JOINTS. *KB UPDATED 2/27/08. *NJ

015300 STEERING:HYDRAULIC POWER ASSIST:POWER STEERING FLUID

POWER STEERING FLUID LEAKS FROM STEERING RACK AND PUMP ATTACHMENT JOINTS. *KB UPDATED 2/27/08. *NJ

NHTSA Safety Investigations, FORD FUSION

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

RQ, Closed , Model Year: 2013

Front Brake Jounce Hose Failures

On August 8, 2022, the Office of Defects Investigation (ODI) opened this investigation based on 50 Vehicle Owner Questionnaires (VOQs) alleging front brake jounce hose ruptures on model year (MY) 2013-2018 Ford Fusion and Lincoln MKZ vehicles. A ruptured front brake hose results in a brake fluid lea... k. As a result, the driver may experience an increase in pedal travel and a reduction in the rate of deceleration, increasing the risk of a crash. It should be noted that the subject vehicles identified fell outside the scope of NHTSA Safety Recall 20V-469, which addressed front brake hoses rupturing on certain MY 2015-2018 Ford Edge and 2016-2018 Lincoln MKX vehicles. The result causes a brake fluid leak, lengthening the distance needing to stop the vehicle, increasing the risk of a crash.On March 10, 2023, Ford Motor Company (Ford) submitted to NHTSA Safety Recall 23V-162 (Ford Recall 23S12) to address front brake jounce hoses that may rupture. Ford found the rupture occurs from a localized failure of the internal reinforcement braid due to cyclic fatigue through tensile/bending and torsional inputs during suspension and steering articulations. The supplier for the front brake jounce hoses is Hitachi. This recall affects the subject vehicles equipped with non-hybrid engines and the suspect front brake jounce hoses (a total of 1,280,726 vehicles). The recall covers subject vehicles built from February 3, 2012 to July 19, 2017 when the suspect hoses were used in vehicle production. The remedy is for dealerships to replace both front brake jounce hoses with new hoses that have a revised braid material at no cost. The vehicles equipped with hybrid engines are excluded from the recall because the internal hose pressure is much lower due to the regenerative braking provided by the hybrid brake system. No failures of brake hoses on hybrid vehicles have been reported to ODI or Ford.Ford's actions address ODIs concerns at this time. Hybrid vehicles will be monitored for related failures. The agency reserves the right to take further action if warranted by new circumstances.The 103 ODI numbers cited above can be viewed at NHTSA.gov under the following ID numbers:11511014, 11510867, 11510318, 11509030, 11505993, 11504989, 11504400, 11502147, 11502082, 11501820, 11501283, 11498439, 11498296, 11496842, 11496335, 11494931, 11494851, 11494252, 11493001, 11492084, 11492070, 11491444, 11491274, 11488858, 11488027, 11487627, 11487416, 11487233, 11486150, 11484924, 11484526, 11484080, 11483948, 11483926, 11483739, 11483723, 11482773, 11482690, 11481077, 11480788, 11480294, 11480052, 11479338, 11479334, 11479252, 11479247, 11479187, 11479094, 11479048, 11478985, 11478953, 11478729, 11478216, 11476892, 11476282, 11470558, 11468994, 11467109, 11466294, 11462746, 11461217, 11456065, 11455367, 11444848, 11436419, 11436376, 11430685, 11428329, 11425083, 11421026, 11420738, 11420735, 11420298, 11418197, 11403926, 11397549, 11366991, 11366757, 11361016, 11359968, 11354569, 11352165, 11350344, 11348799, 11343929, 11343205, 11331947, 11329020, 11319596, 11310529, 11292271, 11288455, 11254787, 11253479, 11253244, 11234622, 11230669, 11230050, 11228240, 11221111, 11143630, 11129392 and 11120228.Read more

EA, Closed , Model Year: 2007

Extended Braking Distance

On April 18, 2018, the Office of Defects Investigation (ODI) opened Engineering Analysis (EA) 18-002 to investigate reports of braking concerns in model year (MY) 2006-12 Ford Fusion and Lincoln MKZ, and MY 2006-11 Mercury Milan vehicles manufactured with Continental Automotive System?s ABS hydrauli... c control units (HCUs). Complainants report that after an ABS braking event (initiated by slippery or uneven surfaces) the brake pedal moved towards the floor and the vehicle stopping distance increased beyond driver expectations.Inside the HCU are four hydraulic normally closed (NC) valves with zinc-coated moving armatures that control the flow of brake fluid. Unstable brake fluid can degrade over time, allow the brake fluid to gel, and corrosion to form on the armatures. The high-viscosity gelation and corrosion can cause the armatures to become stuck (open). In some cases, braking returns to normal when the armature(s) subsequently become unstuck. The intermittent condition proves difficult to diagnose with complainants reporting having (non-HCU) repairs conducted only to have the condition return.During the investigation, 14 HCUs from complaint vehicles were recovered, including seven from reported crashes. NHTSA?s Vehicle Research and Test Center (VRTC) disassembled the HCUs, removed the four NC valves in each, and confirmed 22 of the 56 NC valves contained stuck armatures. On seven of the 14 HCUs, both front wheel armatures were stuck, on nine of the 14 HCUs two or three armatures were stuck. And 52 of the 56 NC armatures exhibited corrosion of the zinc coating. Forces required to extract stuck armatures from the valve sleeve were measured to range from 1.1 to 18.0 lbs. VRTC also conducted ABS braking tests on a variety of test surfaces that showed HCU failures cause increases in pedal travel and braking distances. Testing also showed that if the driver was able to apply four times the brake pedal force and two times the brake pedal travel, then high-vehicle decelerations could be achieved, however, single or multiple wheel lockups were also occurring.Based on Ford?s response to ODI?s July 20, 2018 information request letter, and complainants' reports to NHTSA, ODI identified a population of vehicles with an elevated level of field failure compared to vehicles produced both before and after.Further evaluation of Ford?s response identified that the brake fluid used to produce these vehicles, a specific formulation of a DOT3 fluid provided by CCI Corporation between February 2006 and July 2009, differed from the brake fluid used in other vehicle populations. ODI used the correlation of fluid specification and elevated field failures to identify a vehicle population exhibiting a defect trend. The complaints, crashes and injuries cited above, and the 14 recovered HCUs involve vehicles from this population.On December 18, 2019, Ford submitted safety recall (19V-904) to remedy HCU failures on the MY 2006-2010 Ford Fusion, Lincoln MKZ, and Mercury Milan vehicles manufactured with the suspect CCI brake fluid formulation. Ford will function test the HCU and replace the DOT 3 brake fluid with an improved DOT 4 brake fluid. If the HCU fails the function test, Ford will install an HCU with a different armature coating (black oxide). HCUs with black oxide coating were fully phased into Ford?s new vehicle production by MY 2016; these HCUs do not appear to be experiencing armature corrosion. ODI notes that the non-recalled EA18-002 subject vehicles, which were manufactured with a different specification brake fluid, did not display an elevated level of field failures like the recalled vehicles.Based on available information, Ford?s recRead more

EA, Closed , Model Year: 2010

Power Steering Failure

On September 28, 2016, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE16-011) to investigate claims of power steering assist loss on model year (MY) 2010 Ford Fusion vehicles. During the PE, ODI received 718 unique claims related to the alleged problem with 598 report... Read more

PE, Closed , Model Year: 2014

Steering Wheel Fastening Bolt Loosens

On March 12th, 2018, Ford Motor Company submitted a Defect Information Report to NHTSA describing a defect in the steering wheel fastening system of approximately 1,301,986 model year (MY) Ford Fusion and Lincoln MKZ. On March 1, 2018, Ford discovered a design change that affected the MY 2014-2018 s... Read more

PE, Closed , Model Year: 2007

Extended Braking Distance

On December 20, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation (PE) 16-017 to investigate reports of braking concerns in model year 2007 through 2009 Ford Fusion and Mercury Milan vehicles.Complainants report that after an ABS braking event (caused by braking on a slip... pery or uneven surface) the brake pedal moved towards the floor and the distance in which the vehicle stopped increased beyond what was expected by the driver.The cause of the problem appears to be the Antilock Braking System (ABS) Hydraulic Control Unit (HCU), a component manufactured for Ford by Continental Automotive Systems.Hydraulic control valves within the HCU can experience corrosion and become stuck.In some cases, braking returns to normal when the valve(s) subsequently become unstuck.The intermittent condition proves difficult to diagnose and complainants report having several brake system components replaced only to have the condition return.ODI has identified 544 reports submitted to the agency that relate to this issue in model year 2006-2012 Ford Fusion/MKZ and MY 2006-2011 Mercury Milan, the subject vehicles.Complainants report an increase in pedal travel which in some cases resulted in going past expected stopping points or having to steer to avoid contacting another vehicle; twenty six report a crash with 3 injuries alleged.The Ford reports shown above, which are from PE16-017 and involved the scope discussed above, were similar in content and identified 7 crashes without injury.During PE16-017, ODI was able to recover HCUs from some complaint vehicles, including some from the reported crashes.The recovered HCUs were sent to NHTSA's Vehicle Research and Test Center (VRTC) in East Liberty, Ohio for evaluation.VRTC was able to confirm stuck valves and corrosion of the zinc coated control valves, and it's testing indicates that HCU failures cause increases in pedal travel that may affect braking distance.According to Ford, newer version HCUs have a different coating on the affected valves that do not currently appear to be experiencing corrosion.In it's response to ODI's information request letter, Ford described analysis of two failed HCUs removed from complainant vehicles.In both cases, a gelatinous material found inside the HCU prevented control valves from properly returning to the closed position after actuation.Ford found that an interaction between the valve coating and brake fluid was the likely source of the gelatinous material.It acknowledged that stuck valves can result in increased pedal travel but maintains the affected brake circuit will develop pressure and respond if the brake pedal is pressed sufficiently.While it has not identified an unreasonable risk to safety due to this issue, Ford states that it continues to investigate the possible causal and contributory factors including additional engineering evaluations and testing.An Engineering Analysis has been opened to assess the scope, frequency, and safety-related consequence of the alleged defect.Based on information received during PE16-017, the scope of the investigation has been increased to include another model, the Lincoln MKZ, and to expand the model years of the subject vehicles.Read more

PE, Closed , Model Year: 2010

Power Steering Failure

On September 28th, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation PE16-011 to investigate claims of power steering assist loss on model year 2010 Ford Fusion vehicles.ODI has received 718 unique claims related to the alleged problem with 598 reports indicating the powe... Read more

PE, Closed , Model Year: 2010

Electric power steering failure

The Office of Defects Investigation (ODI) opened a preliminary evaluation to investigate complaints of the loss of power steering while driving. The subject vehicles are equipped with a rack mounted Electric Power Assisted Steering (EPAS) unit.Some of the complaints alleged that the steering assist ... failed and resulted in increased steering efforts that contributed to a loss of control and in some cases a crash.The EPAS system was manufactured by TRW Automotive for Ford and was designated as Generation I.These units were first produced and put into vehicle production in July 2008 beginning with the model year (MY) 2010 Ford Fusion and Mercury Milan.The system is comprised of a mechanical steering rack-and-pinion gear with torque sensor, electric assist motor, motor position sensor and a power steering control module (PSCM). The PSCM is self-monitoring and designed to detect faults within the system and can store diagnostic trouble codes (DTCs) if a problem is detected.There are 29 potential DTCs the system can detect.Many of these allow the system to go into reduced-assist steering mode by using the default vehicle speed signal should the live speed signal be lost, if voltage to EPAS system falls below 10.7 or goes above 17 volts, the temperature at the PSCM goes above 105C (221F), or if high friction is detected.Some DTCs will cause the system to go into manual steering mode (no assist). On July 1, 2015, Ford filed a Defect Information Report (DIR) identifying a safety related defect in TRW GEN I EPAS systems installed in some of the subject vehicles (NHTSA Recall 15V-340, Ford No. 15S18).The DIR indicated that intermittent electrical connections caused by quality issues associated with conformal coat contamination and ribbon cable pin misalignment within the steering gear motor may lead to a loss of the motor position sensor signal, resulting in a sudden loss of power assist while driving.The recall covers approximately 393,623 vehicles built from September 2010 through February 2012:2011-12 Fusion built SEP 2010 - FEB 2012; 2011-12 Lincoln MKZ built SEP 2010 - FEB 2012; 2011 Milan built SEP 2010 - DEC 2010; 2011-13 Taurus built SEP 2010 - FEB 2012; 2011-13 Flex with 3.5L GTDI engine built SEP 2010 - FEB 2012; and 2011-13 MKS, MKT with 3.5L GTDI engine built SEP 2010 - FEB 2012.The repair consists of updating the PSCM software to prevent a loss of steering assist while driving. The revised software will provide audible and visual warnings to the driver. If one or more of the following DTCs are stored, C1B00-62, C200B-2F, C200B-61, C200B-62, C200C-2F, C200D-49, U0300-00, U2011-49, U2011-61, U3000-46, U3000-49, U3000-61, U3000-72, U3000-96, P07AE-09, the dealer will replace the EPAS system at no charge to the owner.ODI's analysis of failure data for this PE identified a total of 2,584 complaints to ODI and Ford and 9,967 Ford warranty claims related to the alleged defect.The recalled vehicles account for 1,634 of the complaints and 7,311 of the warranty claims.ODI's analysis identified 40 complaints alleging crashes that may be related to loss of steering assist while driving, 20 of which involved vehicles included in Ford's recall.The information available for the alleged crashes were not sufficient to assess specific causes of the incidents or to verify EPAS malfunctions in each case.Most of the crashes were low-speed impacts with curbs or roadside objects resulting in wheel or minor body damage.None of the injury claims indicated medical attention was required.In addition, statistical modeling of the failure data by NHTSA's National Center for Statistics and Analysis projected 10-year failurRead more

EA, Closed , Model Year: 2006

Floor mat interference with accelerator

On May 27, 2014, Ford Motor Company submitted recall 14E-028 (Ford recall #14S07) to correct a safety-related problem with certain driver's side Ford optional all-weather floor mats sold for use in model year 2006 through 2011 model year Ford Fusion, Mercury Milan, Lincoln Zephyr, and Lincoln MKZ ve... hicles built at Hermosillo Assembly Plant (HAP) from November 9, 2007, to October 31 ,2010.NHTSA testing determined that the original accessory all-weather mat with a single retention clip (Figure 1), may interfere with accelerator pedal return to idle with the mat retained by the clip and rotated clockwise.Both the single- and double-clip (Figure 2) all-weather floor mats may interfere with the accelerator pedal return to idle when the mats are not secured by the retention clip(s).Testing showed that this can occur if the mats are moved forward from the clipped position approximately two inches into a position in which the rear edge of the mats will abut the retention clip(s) when installed singly and align with the clip(s) when stacked on another floor mat.The pedal interference incidents reviewed by the Office of Defects Investigation (ODI) include 1 crash and 9 incidents with allegations of brake friction materials smoking and/or requiring repair for heat related damage.The crash incident occurred after the parking brake was applied at speed, resulting in loss-of-control vehicle yaw event caused by lock-up of the rear tires.The spin-out resulted in a side impact collision with an oncoming vehicle in an opposing lane of traffic. For the 29 incidents with sufficient information available to make an assessment; 23 (79%) were controlled by the driver either shifting to neutral, turning the engine off, or both; 4 (14%) were ended by the driver either kicking the pedal free (2) or pulling the mat away from the pedal (2); and 2 (7%) were ended by the pedal freeing itself from the mat with no apparent driver action.None of the drivers who reacted to the incident by shifting to neutral or turning the engine off reported any difficulties with either action.The subject mats were sold by Ford and Lincoln dealers directly to customers as an optional accessory equipment item or, beginning in November 2007, the mats were also available as a factory installed accessory if ordered with a new vehicle.Ford estimates that approximately 82,579 affected driver's side all weather floor mats were sold worldwide; either over the counter through Ford dealerships or as original equipment.Owners that purchased the subject all-weather floor mats as a factory installed accessory with their new vehicle will be notified to return their all weather floor mats to their Ford or Lincoln Dealership in exchange for replacement mats.Owners of all other potentially affected vehicles will be notified that, if they have an affected Ford driver's side all weather floor mat, they should return their mats to the dealership in exchange for replacement mats.The VOQs associated with the closing of this investigation are: 10327597, 10332233, 10334211, 10335336, 10339330, 10348772 (and duplicate 10342572), 10372674, 10379562, 10415911, 10426255, 10434107, 10521053, 10554966.This investigation is hereby closed.Read more

EA, Closed , Model Year: 2010

Wheel Mounting Stud Fracture

To date, the agency is aware of 84 consumer complaints and 361 warranty claims related to the alleged defect in the subject vehicles.In total, 382 subject vehicles reportedly experienced one or more wheel stud fractures, resulting in 7 alleged wheel separation incidents.Most of the reported wheel st... ud fractures occurred on subject vehicles originally equipped with 17 inch diameter steel wheels (368 of 382) as did all 7 alleged wheel separation incidents.Of the 7 alleged wheel separation incidents, 5 reportedly involved a wheel becoming detached from the subject vehicle's rear axle.The subject vehicles are designed with a safety margin that requires validation of proper wheel joint function with one missing lug nut and all other lug nuts at the minimum torque specification.If multiple stud fractures occur at a wheel location, analysis of reports indicates that the operator may observe vehicle vibration. If the vibration is ignored and the vehicle continues to be driven the remaining studs may fracture, resulting in a wheel separation.By letter dated December 5, 2011, the manufacturer notified the agency that it will conduct a safety recall (identified by NHTSA Recall No.11V-574 and Ford Recall No. 11S23) on certain 2010 and 2011 model year Ford Fusion and Mercury Milan vehicles to address the potential for wheel separation.The recall vehicles were originally equipped with 17 inch diameter steel wheels and were built from April 1, 2009, through April 30, 2009, and from December 1, 2009, through November 13, 2010.Approximately 128,616 vehicles are potentially affected as well as approximately 2,940 service steel wheels distributed to authorized Ford dealers.Ford has identified two distinct root causes of wheel stud fracture in the recall vehicles.First, certain steel wheel centers may have been stamped improperly such that the mounting pad lacks the necessary concavity, which reduces the diameter of the outermost radial points of contact with the brake rotor.This reduces the Belleville washer effect, which reduces the clamp load of the joint.Second, the wheel mounting face on certain rear brake discs may have been machined improperly due to a damaged dust boot on a gauge that measures rear brake rotor parallelism (flatness), resulting in a wheel mounting face that is convex.One or both conditions may induce bending fatigue in the wheel studs.Ford's analysis of manufacturing process information showed that one or both of these two conditions may have been out of control during parts of one or both production ranges covered by the recall.Owners will be notified by mail and instructed to take their vehicles to an authorized Ford or Lincoln dealer to have the lug nuts replaced on all four wheels with new lug nuts treated with a proprietary low-friction coating that improves clamp load given the same applied torque value, and to have the rear brake discs inspected for wheel mounting surface flatness and replaced, if required.Ford will instruct dealers to notify customers who purchased service steel wheels, where information is available, to return vehicles for lug nut replacement.Accordingly, this investigation is closed.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10364337, 10373257, 10378953, 10381431, 10389641, 10389940, 10392373, 10395676, 10396577, 10400071, 10402309, 10416653, 10419175, 10419734, 10420116, 10424191, 10432393, 10434188, 10436471, 10438725 and 10440830.Read more

PE, Closed , Model Year: 2010

Wheel Stud Fracture

On January 21, 2011, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE11-003) to investigate alleged wheel stud fractures in certain model year (MY) 2010 Ford Fusion vehicles.ODI sent the manufacturer an information request letter dated February 8, 2011 and Ford responded... Read more

PE, Closed , Model Year: 2008

Accel Pedal Interference - Acc Floormat

Unsecured mats may interfere with accelerator pedal return to idle. A heel blocker in the floor pan provides a platform that may lift an unsecured mat into contact with the pedal. Ford introduced new pedals as a running change early in model year (MY) 2010 vehicles. Analysis of complaints received b... Read more

FORD FUSION - All Years Overview

Complete safety history for the FORD FUSION across all model years (2006, 2020).

127 Total Recalls

28,651 Total Complaints

11 Investigations

1,206 Reported Crashes

307 Reported Fires

20 Reported Deaths

FORD FUSION - Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2020	3	260	View
2019	3	401	View
2018	2	567	View
2017	4	1,375	View
2016	13	2,047	View
2015	13	1,266	View
2014	19	1,752	View
2013	19	2,366	View
2012	6	3,048	View
2011	9	3,651	View
2010	13	7,025	View
2009	7	1,165	View
2008 (current)	6	1,532
2007	5	1,277	View
2006	5	919	View

Other FORD Models

Model	Recalls	Complaints
MUSTANG	1,104	11,600	View
RANGER	928	10,371	View
F-350 SD	776	2,363	View
F-450 SD	692	624	View
F-150	692	46,142	View
F-250 SD	638	3,635	View
EXPLORER	624	42,549	View
F-550 SD	578	603	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

2008 FORD FUSION

Complaint Statistics

Top Reported Components

EPA Fuel Economy, 2008 FORD FUSION

Technical Service Bulletins, 2008 FORD FUSION

Most Affected Components

NHTSA Safety Investigations, FORD FUSION

FORD FUSION - All Years Overview

FORD FUSION - Year by Year

Other FORD Models