2011 FORD FUSION

9 recalls, 3,651 complaints - 91 TSBs - 4/5 safety rating

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

AIR BAGS:FRONTAL

Defect Description

Ford Motor Company (Ford) is recalling certain air bag inflator and/or module replacement service parts that may have been used as part of a collision repair. The parts include certain driver-side air bag inflators and/or modules, designed to fit 2005-2014 Ford Mustang and Mustang GT500. It also i... Read more

Consequence

Remedy

Ford will notify dealers that purchased the affected parts, and dealers will provide replacement parts to purchasers, free of charge. The recall began March 18, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.

249 vehicles affected

Manufacturer: Ford Motor Company

AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Defect Description

Ford Motor Company (Ford) is recalling certain 2014 Ford Mustang vehicles sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Vi... 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

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. The recall began February 13, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's num... Read more

782,384 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

FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK

Defect Description

Ford Motor Company (Ford) is recalling certain model year 2010-2011 Ford Fusion vehicles manufactured July 21, 2008, to March 4, 2011, and 2010-2011 Mercury Milan vehicles manufactured July 23, 2008, to December 10, 2010. The affected vehicles have fuel vapor canisters whose purge valves may not op... Read more

Consequence

The pressure changes may cause the tank to crack and leak fuel. A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy

Ford will notify owners, and dealers will update the vehicle powertrain control modules and inspect the vehicle for any diagnostic trouble codes (DTCs) for this issue and perform a leak test on the Canister Purge Valve (CPV). The fuel tank will be inspected for cracks. The CPV and fuel tank will b... Read more

411,205 vehicles affected

Manufacturer: Ford Motor Company

STEERING:ELECTRIC POWER ASSIST SYSTEM

Defect Description

Ford Motor Company (Ford) is recalling certain model year 2011-2012 Ford Fusion vehicles without a 3.5L engine and Lincoln MKZ hybrid electric vehicles, 2011 Mercury Milan vehicles, 2011-2012 Ford Taurus, Ford Flex, Lincoln MKS, and Lincoln MKT vehicles equipped with a 3.5L GTDI engine and 2013 Ford... Read more

Consequence

If the vehicle experiences a loss of power steering assist, extra steering effort will be required at lower speeds, increasing the risk of a vehicle crash.

Remedy

Ford will notify owners, and dealers will check the Power Steering Control Module (PSCM) for Diagnostic Trouble Codes (DTC). If dealers find any loss of steering assist DTCs, the steering gear will be replaced, free of charge. If, no codes are found during the PSCM inspection, the PSCM software w... Read more

393,623 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

WHEELS:LUGS/NUTS/BOLTS/STUDS

Defect Description

FORD IS RECALLING CERTAIN MODEL YEAR 2010-2011 FORD FUSION AND MERCURY MILAN VEHICLES EQUIPPED WITH 17 INCH STEEL WHEELS AND BUILT FROM APRIL 1, 2009, THROUGH APRIL 30, 2009, AND FROM DECEMBER 1, 2009, THROUGH NOVEMBER 13, 2010. THE WHEEL STUDS MAY FRACTURE, POTENTIALLY CAUSING A WHEEL TO SEPARATE.

Consequence

WHILE DRIVING, MULTIPLE STUD FRACTURES COULD OCCUR AT THE WHEEL LOCATION, AND THE OPERATOR MAY EXPERIENCE VEHICLE VIBRATION AND/OR WHEEL SEPARATION, INCREASING THE RISK OF A CRASH.

Remedy

FORD WILL NOTIFY OWNERS, AND DEALERS WILL INSPECT THE REAR BRAKE DISC SURFACE FOR FLATNESS AND REPLACE THE DISCS AS NECESSARY. ADDITIONALLY, THE WHEEL LUG NUTS WILL BE REPLACED ON ALL FOUR WHEELS. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR ABOUT JANUARY 24, 2012. OWNERS MAY CONTACT THE FORD MOTO... Read more

128,616 vehicles affected

Manufacturer: FORD MOTOR COMPANY

Complaint Statistics

3,651 total complaints 121 crashes 17 fires 68 injuries 1 deaths

Top Reported Components

Component	Complaints
STEERING	1,236
AIR BAGS	324
ENGINE	320
POWER TRAIN	277
VEHICLE SPEED CONTROL	259
ELECTRICAL SYSTEM	204
FUEL/PROPULSION SYSTEM	189
SERVICE BRAKES	157
UNKNOWN OR OTHER	122
ELECTRONIC STABILITY CONTROL (ESC)	93

Incident date: Jul 4, 2026

On July 4, the electrical system under the dash caught fire and burned the ignition and dash, all the electrical under the dash

Incident date: Mar 22, 2026

See attached document for complaint.

Incident date: Jun 17, 2026

Having loss of power steering assist the advanced trac peering steering says service now I feel it should fall under a recall cause I took it to a mechanic shop and they told me they ford fusion have issues with the power assist steering cause it goes out

Incident date: Jun 4, 2026

My 2016 GMC Terrain 2.4L Ecotec first stalled while idling at a red light in Raleigh, NC. I restarted it and it sounded different, so I drove it home. The next morning it would not start. The failure occurred at approximately 69,939 miles with no meaningful warning. The dealer’s diagnostic report... Read more

Incident date: Jun 4, 2026

The driver side headlight low beam LED stopped functioning. I noticed moisture inside the headlight housing. I bought a replacement headlight unit and a control module. The replacement headlight housing has also had the low beam go out, again. Now I have to purchase a module to see if the headlight ... Read more

Incident date: Jun 1, 2026

There was a previous recall for camera system that was fixed using a OTA over the air update per JEEP. This update introduced new problems It disabled the forward collision detection and disabled paddle shifting and other safety features which should also be issued as a RECALL because the dealer is ... Read more

Incident date: May 3, 2026

The contact owns a 2023 Grand Design 5th Wheel. The contact stated that the propane gas pigtail was on the floor and created an electrical spark and popping noise that traveled up to other cords. The contact stated that the pigtail cord was improperly fitted and should not have been on the floor. Th... Read more

Incident date: Jan 21, 2026

After only 880 miles, the clutch and cylinder have failed.

Incident date: Apr 19, 2026

Infotainmeny system receives multiple fals touches and switches to other screens and functions with no direct input from me the driver. This is very distracting and also dangerous as the issue also interfears with navigation, it will turn is off and switch destinations without any input. This issue ... Read more

Incident date: Apr 10, 2026

Upon delivery of a brand new 2026 Hyundai Ioniq 5 with 13 miles on the odometer, the washer fluid warning illuminated the next day. Reservoir was refilled on 3/29 and was completely empty by 3/30. Vehicle was brought to the authorized dealer on 3/31. The technician confirmed via repair order that th... Read more

Incident date: Apr 10, 2026

Incident date: Apr 11, 2026

Back rear glass shattered for no reason is it due to faulty rear suspension or poor glass quality vehicle only has 9200 miles

Incident date: Feb 20, 2026

I own a 2026 Hyundai Palisade Hybrid Calligraphy. A recent over-the-air software update removed the ability to control rear seats through the infotainment system, which was a key feature at the time of purchase. This change was made without meaningful notice or consent and significantly alters how ... Read more

Incident date: Dec 3, 2025

Entered vehicle through driver’s side door. Put car in reverse and backed out of parking space. As the driver put the car into drive, we advanced approximately 25 yards, the rear tailgate opened and lifted without alerting the driver. No warnings, alarms or dash board notifications. Since we were ... Read more

Incident date: Mar 14, 2026

My 2023 Mercedes-Benz EQB 300 (VIN [XXX] ) is subject to a high-voltage battery safety recall involving a risk of internal short circuit and fire. Mercedes-Benz has acknowledged that the battery pack in affected vehicles can fail at high state of charge and may cause a thermal event while driving or... Read more

Incident date: Mar 14, 2026

The contact owns a 2021 Ford Bronco Sport. The contact stated that while driving 15 MPH in traffic, the accelerator pedal was depressed; however, the vehicle failed to respond as needed. The contact stated that the vehicle was in Fuel Saver Mode, and the vehicle turned off unexpectedly and failed to... Read more

Incident date: Mar 11, 2026

Driver side passenger back sliding door will not open or close properly. Door will jam and make a loud noise or will not open when trying to open. Took it the dealership 4 times they replaced the motor but the issue continues.

Incident date: Mar 9, 2026

The contact owns a 2021 Hyundai Kona. The contact stated that while driving at a slow speed or making a turn, the vehicle stalled. In addition, there was an abnormal ticking sound coming from the engine. There was an unknown code displayed on the instrument panel. Most recently, the engine started c... Read more

Incident date: Mar 4, 2026

Exhaust fumes and stink on cold start . vehicle only has 40,000 mi and I have exhaust smells coming in through hvac system!!

Incident date: Mar 4, 2026

Powertrain light came on and threw code p1450 and car went into limp mode. Car will stall at stops and lights and won't go over 40. Replaced the canister purge valve which turned light off but it immediately came back once trying to over 40 and went back into limp mode. Everything I have read and ai... Read more

Incident date: Mar 4, 2026

Exhaust fumes and stink on cold start . vehicle only has 40,000 mi and I have exhaust smells coming in through hvac system!!

Incident date: Mar 3, 2026

Car continues to accelerate after applying the brake. Has happened numerous times. Usually at slow speed

Incident date: Mar 3, 2026

I brought my 2014 Honda Accord to Honda of Westport (authorized dealer) to complete the active driveshaft safety recall. The dealer informed me the recall COULD NOT be performed unless I first paid $708.31 out of pocket to replace both front ball joints. I was given no choice - pay or leave with the... Read more

Incident date: Mar 3, 2026

Incident date: Feb 26, 2026

Hesitates to start

Incident date: Feb 14, 2026

ICCU failure at 5308 miles. heard a loud pop while driving and 12v warning system errors

Incident date: Feb 16, 2026

The contact owns a 2023 Hyundai Palisade. The contact received notification of NHTSA Campaign Number: 25V607000 (Seat Belts); however, the part to do the recall repair was not yet available. The contact stated that occasionally, while driving at various speeds, the front driver's side seat belt buck... Read more

Incident date: Feb 16, 2026

The contact owns a 2024 Toyota Prius Hybrid equipped with Bridgestone Tires, Tire Line: Ecopia EP422, Tire Size: 195/60/R17, DOT Number: Y9CDCJTX. The contact stated that while the vehicle was in for routine maintenance, during the tire rotation, the mechanic discovered that one of the front tires h... Read more

Incident date: Feb 6, 2026

Drivers door became hard to open and close. Found driver front door stop damaged / welds broken and separated from door interior.

Incident date: Oct 19, 2021

I was driving on the highway with no one in front of me. The car suddenly slammed on the brakes and flashed "emergency breaking system" on my dash. My car went from about 75 mpg down to 50. The car behind me almost rear-ended me. He then proceeded to pass me and brake check me because he thought I h... Read more

Incident date: Oct 19, 2021

My wife and I were driving to the dealer to have a safety recall service performed on her Jeep Wrangler 4XE. We had just merged onto the highway, I was in my car, behind my wife in her Jeep. Less than a mile onto the highway, my wife suddenly slowed down and moved to the right lane. As she moved ... Read more

Incident date: Jan 2, 2026

My Ford Fusion has the 1.5L ecoboost engine. This engine has engineering issues that are known to Ford. My vehicle started producing white smoke from the exhaust and sluggish performance. At approximately 105,000 miles my vehicle went into limp mode due to a cracked head gasket. This was due to cool... Read more

Incident date: Dec 1, 2025

The contact owns a 2024 GMC Canyon equipped with Goodyear Tires, Tire Line: Wrangler Territory, Tire Size: 265/65/R18, DOT number: 1M6C8JT1R. The contact stated that while her husband was driving at an undisclosed speed, the TPMS indicated a low tire pressure. The driver pulled over and noticed that... Read more

Incident date: Dec 1, 2025

The contact owns a 2018 Ram 2500. The contact received notification of NHTSA Campaign Number: 24V896000 (Service Brakes, Hydraulic); 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: Dec 1, 2025

While the manufacture states parts are available, I have not been able to get any and have been waiting since October of 2025. NHTSA Recall Number25V512

Incident date: Dec 30, 2025

What component or system failed or malfunctioned, and is it available for inspection upon request? THE THROTTLE FAILED ON THE FREEWAY DUE TO A BREAK IN THE ENGINE HARNESS. HAVE FULL REPAIR RECEIPTS FROM SHOP. How was your safety or the safety of others put at risk? FULL ENGINE AND THROTTLE FAILURE O... Read more

Incident date: Dec 30, 2025

Transmission is failing after being rebuilt. Has only 50,000 miles. It stalls if braking hard. Shifts hard and shudders. Has been serviced and checked by a mechanic.

Incident date: Dec 19, 2025

I am reporting a driver distraction safety issue involving the infotainment system in my 2024 GMC Canyon. The vehicle displays a mandatory “Focus your attention on driving” warning every time the vehicle is started, requiring user acknowledgment. When using the built-in Google Maps navigation... Read more

Incident date: Nov 4, 2025

My vehicle had a faulty PCV valve that was under "Stop Drive," order. I received no correspondence from the NHTSA nor from BMW of North America in regards to this. My BMW X-5 had significant issues that are directly associated with this issue. After contacting BMW of North America directly because... Read more

Incident date: Oct 23, 2025

Since the recall was announced, my truck has experienced constant ABS and traction control alarms, including an unending beeping warning chime that makes the vehicle unpleasant and unsafe to drive. My local Ram dealer confirms that the repair parts (HCU/ABS module) are not available and that there i... Read more

Incident date: Oct 24, 2025

Engine is loosing oil into the #2 cylinder, causing an damage to the downstream exhaust. Once the cylinder fills with oil, the care immediately drops in operation speed causing significant driver response and immediately surrounding vehicles

Incident date: Oct 24, 2025

Was driving on the highway, heard loud bang followed by a violent metal-on-metal slapping or knocking sound, and a sudden loss of engine power. Came to find it was crankshaft/connecting rod issue that is common in these vehicles. Have a picture of the broken rod and am waiting the get it repaired.

Incident date: Jun 9, 2025

Car stopped driving correctly and the transmission now needs replaced

Incident date: Oct 13, 2025

Vehicle: 2019 Kia Soul 2.0L GDI VIN: [XXX] Mileage: 92,200 The engine and connecting rod bearings failed — a known defect in Kia’s Theta II GDI engines. The vehicle began making a loud knocking noise and would stall when turning to start the engine within days of purchase. This is consistent w... Read more

Incident date: Jun 18, 2025

SHIFT TO PARK

Incident date: Sep 30, 2025

As I am driving, does not matter speed or weather, the instrument cluster screen will do a "System Check" as if the vehicle is being started. The screen will go blank for about 5 seconds and then will reappear. If the vehicle is in cruise control, that will disengage and the vehicle will slow down a... Read more

Incident date: Sep 10, 2025

Vehicle has an oil leak due to a faulty vacuum pump and gasket which is causing the vehicle to leak an excessive amount throughout the engine and other components. It was seen by a repair shop and they pinpointed the leak. This could cause an engine to stall while driving if not fixed soon which cou... Read more

Incident date: Sep 24, 2022

Car has died 10+ times in the last 2 weeks. Will not hold a charge and it’s getting to the point that my car is dying in the middle of the road, during heavy traffic. That or the car will just not start unless jumped

Incident date: Sep 24, 2022

Showing 50 of 3,651 complaints.

NHTSA Safety Ratings, 2011 FORD FUSION

2011 Ford Fusion 4 DR AWD

Category	Rating
Overall Rating	4 / 5 ★★★★☆
Frontal Crash	3 / 5 ★★★☆☆
Frontal Crash, Driver	4 / 5 ★★★★☆
Frontal Crash, Passenger	3 / 5 ★★★☆☆
Side Crash	4 / 5 ★★★★☆
Side Crash, Driver	5 / 5 ★★★★★
Side Crash, Passenger	3 / 5 ★★★☆☆
Rollover	5 / 5 ★★★★★
Rollover Risk	9.2%

Safety Technology

Feature	Status
Electronic Stability Control	Standard
Forward Collision Warning	No
Lane Departure Warning	No

Source: NHTSA 5-Star Safety Ratings Program. Ratings are based on crash tests conducted by the National Highway Traffic Safety Administration.

Technical Service Bulletins, 2011 FORD FUSION

91 manufacturer communications from 52 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
061000 ENGINE AND ENGINE COOLING:ENGINE	9
350000 EQUIPMENT	8
103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)	6
060000 ENGINE (PWS)	6
118000 ELECTRICAL SYSTEM:SOFTWARE	6
100000 POWER TRAIN	4
010000 STEERING	4
117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL	3

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?

010000 STEERING

Some 2010-2012 Fusion/Milan and 2011-2012 MKZ vehicles equipped with a 2.5L or 3.0L engine and electronic power assist steering (EPAS), a remanufactured replacement steering gear (MU2Z-3V504-ARM) is available which is significantly less exp

119810 ELECTRICAL SYSTEM:PROPULSION SYSTEM:HYBRID MANAGEMENT:POWER CONTROL UNIT/MODULE (HPCU)

Some 2010-2012 Fusion hybrid electric vehicles (HEV), 2010-2011 Milan HEV and 2011-2012 MKZ HEV vehicles may experience reduced electric vehicle operation and increased gasoline engine operation around 10 years of vehicle age and beyond. Th

100001 HYBRID PROPULSION SYSTEM

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

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

132000 VISIBILITY:GLASS, SIDE/REAR

Some 2010-2020 vehicles may exhibit distorted glass with a subtle orange peel pattern or streaking etched into the surface. This is caused by hydrofluoric acid which is used in some car wash solutions as a cleaning agent. Hydrofluoric acid

130000 VISIBILITY

100000 POWER TRAIN

On vehicles equipped with an automatic transmission it is imperative that the converter pilot hub be greased with Motorcraft Multi-Purpose Grease Spray XL-5-A even if grease was not applied from the factory. Also verify that the engine/tran

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

353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

2010-2018 various vehicles equipped with SYNC or SYNC 3 may not function when attempting to find or use the Spotify app via AppLink. As of an update released on 1/15/2018 Spotify will no longer be supporting their AppLink integration. No re

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

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

010000 STEERING

SOME 2010-2016 EPAS EQUIPPED VEHICLES MAY EXHIBIT STEERING RELATED NOISES. THE WORKSHOP MANUAL (WSM) DIAGNOSTIC PROCEDURES HAVE BEEN UPDATED IN SECTION 211-02. WHEN DIAGNOSING AND REPAIRING EPAS STEERING NOISES USE THE UPDATED PROCEDURES.

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)

350000 EQUIPMENT

SOME 2010-2012 FUSION HYBRID, MILAN HYBRID AND MKZ HYBRID VEHICLES MAY EXHIBIT AN ILLUMINATED MALFUNCTION INDICATOR LAMP (MIL) WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0030 AND/OR P0130. FOLLOW THE SERVICE PROCEDURE STEPS TO CORRECT THE CONDIT

060000 ENGINE (PWS)

CERTAIN 2011-2012 MODEL YEAR FUSION VEHICLES EQUIPPED WITH 2.5L OR 3.0L ENGINES - POWERTRAIN CONTROL MODULE REPROGRAMMING AND CANISTER PURGE VALVE INSPECTION

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

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 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

062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

062200 ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

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

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

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

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

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

060000 ENGINE (PWS)

100000 POWER TRAIN

6F35 TRANSMISSION - FLUID LEAK AT LEFT SIDE HALFSHAFT SEAL BUILT ON OR BEFORE 10/14/2013 ISSUE Some 2009-2014 Escape, 2009-2011 Mariner, 2010-2014 Fusion, 2010-2011 Milan, 2012-2014 Edge/Explorer, and 2013-2014 Taurus/MKT/MKZ vehicles b

133000 VISIBILITY:POWER WINDOW DEVICES AND CONTROLS

FORD: NO SERVICE ACTION IS RECOMMENDED FOR THIS CONDITION. PLEASE USE AT YOUR DISCRETION. VARIOUS 2010-2015 VEHICLES MAY EXPERIENCE A TURBULENCE NOISE, SIMILAR TO AN HELICOPTER NOISE, AT HIGHWAY SPEEDS WHEN THE REAR DOOR WINDOW(S) OR SUNROO

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

FORD 2009-2014 ESCAPE, 2010-2014 FUSION, 2012-2014 EDGE, EXPLORER, 2013-2014 TAURUS: LINCOLN 2013-2014 MKT,MKZ: MERCURY 2009- 2011 MARINER, 2010-2011 MILAN. SOME VEHICLES EQUIPPED WITH 6F35 AUTOMATIC TRANSMISSION MAY EXHIBIT A FLUID LEAK F

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

LINCOLN/FORD: SOME VEHICLES WILL EXPERIENCE, IN HOT EXTREME AMBIENT TEMPERATURES, A STOP SAFELY NOW OR A MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED IN PRESENT OF BATTERY ENERGY CONTROL MODULE (BECM) DTC P0A7E AND BECM NEEDS REPLACED, AND

118000 ELECTRICAL SYSTEM:SOFTWARE

FORD/LINCOLN: THERE IS AN EXTENDED WARRANTY COVERAGE FOR THE LOSS OF ABS SPEED SIGNAL RELATED COMMUNICATION THAT DISABLE OBDII SYSTEM MONITORS FOR PCM REPROGRAMMING. MODEL 2011-14 F-SUPER DUTY, ESCAPE, TAURUS, FUSION, MKT, MKZ. *PE

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

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

350000 EQUIPMENT

FORD: THE THROTTLE BODY INTERNAL MOTOR CONTACTS MAY BE CONTAMINATED, RESULTING IN AN ELECTRICAL, INTERMITTENT, CONNECTIVITY, CAUSING MALFUNCTION INDICATOR LAMP (MIL) OR WRENCH LIGHT TO BE ILLUMINATED. MODEL 2009-2012 FUSION, MILAN, ESCAP

118000 ELECTRICAL SYSTEM:SOFTWARE

LINCOLN/FORD: IN POWERTRAIN CONTROL MODULE (PCM), THAT ALLOWS ANTI LOCK BRAKE SYSTEM (ABS) AND OUTPUT SHAFT SPEED SENSOR (OSS) SIGNAL FAULTS, A SOFTWARE ERROR HAS OCCUR AND DISABLED ON BOARD DIAGNOSTIC (OBD) MONITORS WITH NO ILLUMINATION O

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

MERCURY/FORD: ON SOME VEHICLES, THERE IS A FLUID LEAKAGE, COMING FROM LEFT HAND (LH) HALFSHAFT SEAL OF THE AUTOMATIC TRANSMISSION AND A SERVICE KIT IS AVAILABLE NOW, FOR REPAIR. MODEL 2009-2012 ESCAPE, MARINER, FUSION, MILAN. *PE

117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

FORD: THROTTLE BODY WILL DEVELOP CONTAMINATION ON INTERNAL MOTOR CONTACTS RESULTING IN AN INTERMITTENT ELECTRICAL CONNECTIVITY AND MALFUNCTION INDICATOR LAMP (MIL) OR WRENCH LIGHT WILL ILLUMINATE. MODEL 2009-2013 FUSION, MILAN, ESCAPE, MA

110000 ELECTRICAL SYSTEM

060000 ENGINE (PWS)

FORD: DUE TO AN INTERMITTENT LOSS OF RPM OR LACK OF ACCELERATION, IN SOME VEHICLES, WITH ILLUMINATED WRENCH LIGHT, DIAGNOSTIC TROUBLE CODES (DTCS) P2111, P2112 MAY OR MAY NOT BE STORED IN POWERTRAIN CONTROL MODULE (PCM). MODELS 2009-12 ES

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

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

FORD: ON THE LEFT HAND HALF SHAFT SEAL, THERE IS A FLUID LEAK FROM THE TRANSMISSION BECAUSE OF WEAR ON CASE BUSHING. MODEL 2009-2012 ESCAPE, 2009-2011 MARINER, 2010-2012 FUSION, 2010-2011 MILAN. *PE

100000 POWER TRAIN

6F35 Transmission - Fluid leak at left side halfshaft seal - built on or before 10/14/2013

356000 EQUIPMENT ADAPTIVE/MOBILITY

FORD: ON VARIOUS VEHICLES WITH MY TOUCH,AFTER ANY APIM PROGRAMMING, REPLACEMENT OR DISCONNECT FROM FRONT DISPLAY INTERFACE MODULE (FDIM), TOUCHSCREEN CALIBRATION MUST BE PERFORMED. MODEL YEARS 2011-2013. NO MODELS LISTED.

350000 EQUIPMENT

060000 ENGINE (PWS)

FORD/LINCOLN/MERCURY: SOME VEHICLES MAY EXPERIENCE AN ILLUMINATED MIL OR SAFETY STOP NOW MESSAGE, OR A NO START CONDITION OR POSSIBLE MISFIRE OR ROUGHNESS AT IDLING THROUGH 2000RPM OR A LACK OF ACCELERATION. MODELS 2009-12 ESCAPE, 2009-1

060000 ENGINE (PWS)

FORD/LINCOLN: A DIAGNOSTIC TROUBLE CODE (DTC) P0A0A (HIGH VOLTAGE SYSTEM INTERLOCK CIRCUIT) SHOWS WHEN CERTAIN VEHICLES EXPERIENCE RED TRIANGLE ON/STOP SAFELY NOW MESSAGE AND/OR A CONDITION OF NO START. *PE

110000 ELECTRICAL SYSTEM

060000 ENGINE (PWS)

FORD/MERCURY/LINCOLN: SOME VEHICLES EXHIBIT A COLD WEATHER PHENOMENON WHERE FLUID HAS EXPELLED OUT OF VENT ON REAR DRIVE UNITS (RDU) AND FLUID, ON OCCASION, WOULD BURP OUT. *PE

061000 ENGINE AND ENGINE COOLING:ENGINE

FORD/MERCURY/LINCOLN: SOME MODEL YEAR VEHICLES MAY EXHIBIT A MESSAGE WITH A RED TRIANGLE ON AND STOP SAFELY NOW, AND/OR HAVE A DIAGNOSTIC TROUBLE CODE, NO START CONDITION. *PE

117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

FORD/MERCURY/LINCOLN: SOME MODEL YEAR VEHICLES MAY EXHIBIT A MESSAGE WITH A RED TRIANGLE ON AND STOP SAFELY NOW, AND/OR HAVE A DIAGNOSTIC TROUBLE CODE, NO START CONDITION. *PE

061000 ENGINE AND ENGINE COOLING:ENGINE

FORD: THE VARIABLE CAMSHAFT TIMING VCT) SOLENOID MOVEMENT MAY BE TEMPORARILY RESTRICTED DUE TO DEBRIS IN ENGINE OIL THAT IS CAUSING DIAGNOSTIC TROUBLE CODES (DTCS). *PE

125000 EXTERIOR LIGHTING:BRAKE LIGHTS

MERCURY/LINCOLN/FORD: THE RED BRAKE LAMP WILL ILLUMINATE WITH NO CHANGE IN BRAKE PEDAL FEEL. *PE

021530 SUSPENSION:FRONT:CONTROL ARM:LOWER ARM

LINCOLN/FORD: STEERING SYSTEM SENSES, HALF FRONT LOWER CONTROL ARMS/REARWARD IS EXPERIENCING A HIGHER FRICTION CONDITION AND CAUSING THE INSTRUMENT CLUSTER STABILITY/TRACTION TO ILLUMINATE. MODEL 2011-2012 FUSION, MKZ. *PE

117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

010000 STEERING

061000 ENGINE AND ENGINE COOLING:ENGINE

FORD: AFTER REFUELING VEHICLE, WOULD BE HARD TO START, RUNS ROUGH AND AN AUDIBLE CLICKING NOISE CAN BE HEARD. *PE

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

FORD: ENGINE POWER MAY BE REDUCED WITH A HIGH IDLE SPEED. THE ENGINE LIGHT MAY ALSO BE ON WITH A STORED TROUBLE CODE. PROGRAMMING ISSUE. 2010-2011 FUSION/MERUCRY MILAN/LINCOLN MKZ. *RM

112000 ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR

FORD: ENGINE POWER MAY BE REDUCED WITH A HIGH IDLE SPEED. THE ENGINE LIGHT MAY ALSO BE ON WITH A STORED TROUBLE CODE. PROGRAMMING ISSUE. 2010-2011 FUSION/MERUCRY MILAN/LINCOLN MKZ. *RM

118000 ELECTRICAL SYSTEM:SOFTWARE

FORD: ENGINE POWER MAY BE REDUCED WITH A HIGH IDLE SPEED. THE ENGINE LIGHT MAY ALSO BE ON WITH A STORED TROUBLE CODE. PROGRAMMING ISSUE. 2010-2011 FUSION/MERUCRY MILAN/LINCOLN MKZ. *RM

136000 VISIBILITY:WINDSHIELD WIPER/WASHER

FORD: 2010-2011 FUSION. SERVICE ENGINE SOON LIGHT IS ON WITH THREE POSSIBLE TROUBLE CODES STORED DURING WINDSHIELD WIPER USE. *RM

061000 ENGINE AND ENGINE COOLING:ENGINE

FORD: 2011 FUSION/ESCAPE. MALFUNCTION LIGHT IS ON AND ENGINE IS MISFIRING OR RUNNING ROUGH. A TROUBLE CODE IS STORED. *RM

118000 ELECTRICAL SYSTEM:SOFTWARE

COMM-TRANS LUND: SOME 2009-2011 MODELS MAY HAVE THE AIR BAG INICATOR FLASHING WITH A STORED TROUBLE CODE. THIS IS A SOFTWARE PROBLEM. *RM

140000 AIR BAGS

COMM-TRANS LUND: SOME 2009-2011 MODELS MAY HAVE THE AIR BAG INICATOR FLASHING WITH A STORED TROUBLE CODE. THIS IS A SOFTWARE PROBLEM. *RM

061000 ENGINE AND ENGINE COOLING:ENGINE

FORD: THERE MAY BE A LEAKING/STUCK CANISTER PURGE VALVE WHICH CAN CAUSE MULTIPLE DRIVING SYSTEMS. THE MALFUNCTION LIGHT MAY BE ON WITH OR WITHOUT STORED TROUBLE CODES. *RM

162300 STRUCTURE:BODY:DOOR

FORD: 2011 FUSION/MKZ/MILAN. EXTERIOR DOOR HANDLE MAY STICK WHEN OPENING OR WILL NOT BE FLUSH WHEN CLOSED. *RM

162310 STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS

FORD: 2011 FUSION/MKZ/MILAN. EXTERIOR DOOR HANDLE MAY STICK WHEN OPENING OR WILL NOT BE FLUSH WHEN CLOSED. *RM

010000 STEERING

FORD: THERE MAY BE A STEERING DRIFT WHILE DRIVING ON A FLAT OR UNEVEN ROAD SURFACE. 2010-2011 FUSION/MILAN/MKZ. THIS COULD BE NORMAL. *RM

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

061000 ENGINE AND ENGINE COOLING:ENGINE

FORD: THERE MAY BE A HARD START OR ROUGH IDLE ACCOMPANIED WITH TWO TROUBLE CODES. THE PROBLEM MAY HAVE TO DO WITH CAMSHAFT TIMING. 2010-2011 FUSION/ESCAPE/MILAN/MARINER. *RM

063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

FORD: VEHICLES MAY RUN ROUGH, HARD START AFTER REFUELING, CLICKING NOISE UNDER HOOD, AND HAVE TROUBLE CODES STORED. *RM

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

FORD: THERE MAY BE A LOSS OF POWER, HESITATION, SURGE, OR LACK OF THROTTLE RESPONSE WHILE DRIVING. THE BRAKE OVER ACCELERATOR FEATURE MAY BE ACTIVATING. *RM

061000 ENGINE AND ENGINE COOLING:ENGINE

FORD: THE IDLE SPEED DROPS LOWER THAN DESIRED AND MAY FLUCTUATE. THERE MAY BE TWO POSSIBLE TROUBLE CODES STORED. *RM

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

FORD: THERE MAY BE A WRENCH LIGHT ON WITHOUT DRIVEABLE SYMPTOMS, BUT AN INTERNAL CODE STORED. *RM

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 (current)	9	3,651
2010	13	7,025	View
2009	7	1,165	View
2008	6	1,532	View
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

2011 FORD FUSION

Complaint Statistics

Top Reported Components

NHTSA Safety Ratings, 2011 FORD FUSION

Safety Technology

Technical Service Bulletins, 2011 FORD FUSION

Most Affected Components

NHTSA Safety Investigations, FORD FUSION

FORD FUSION - All Years Overview

FORD FUSION - Year by Year

Other FORD Models