2012 FORD FUSION

6 recalls, 3,048 complaints - 84 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 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

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

Complaint Statistics

3,048 total complaints 163 crashes 20 fires 105 injuries 8 deaths

Top Reported Components

Component	Complaints
STEERING	1,181
AIR BAGS	409
POWER TRAIN	178
ELECTRICAL SYSTEM	175
ENGINE	169
UNKNOWN OR OTHER	157
SERVICE BRAKES	106
VEHICLE SPEED CONTROL	91
ELECTRONIC STABILITY CONTROL (ESC)	80
STRUCTURE:BODY	80

Incident date: Jun 22, 2026

My car does not always respond when the brakes are tapped. They are soft/squishy at times and I have to push the pedal all the way to the floor for the car to stop. This issue has been occuring off & on for approximately 3 years though it's been more frequent since June of 2026. I have never seen an... Read more

Incident date: Jun 28, 2026

The contact owns a 2012 Ford Fusion. The contact stated that while driving 50 MPH, the vehicle lost power steering functionality and almost caused a crash. The message "Service Power Steering Now" was displayed. The contact was able to drive to the destination. The contact stated that the vehicle ha... Read more

Incident date: Jun 18, 2026

unknown. just bought this car

Incident date: May 30, 2026

Brake system. Pedal is soft and braking force to stop is reduced. Yes, at first they thought it was the brake booster, and know thinking it is the master cylinder, now they aren't even sure what it might be. Ford dealership techs. No, pedal was "squishy" when braking

Incident date: Sep 8, 2025

I was just driving and I lost power steering, it was incredibly difficult to steer and it was Heavy Steering, and warnings appeared on the dash.

Incident date: Sep 8, 2025

I was just driving and I lost power steering, it was incredibly difficult to steer and it was Heavy Steering, and warnings appeared on the dash.

Incident date: Sep 8, 2025

I was just driving and I lost power steering, it was incredibly difficult to steer and it was Heavy Steering, and warnings appeared on the dash.

Incident date: Jan 1, 2026

The outside door handles are defective, and Honda is aware of the issue. In warm or hot weather, the door opening mechanism binds up, and eventually the stress is too great and it causes the door handle to break. The problem has been reported by nearly every CR-Z owner. For more incidents, pleas... Read more

Incident date: Jan 1, 2026

Se traba y se pone duro el "gobierno" junto con la cremallera electroasistida el volante no gira ni con el carro prendido, no eh echo uso de la campaña 15S18, nunca ah Sido asistido por el fabricante Ford, ni mucho menos lo eh metido a un taller de servicio independiente ni con aseguradoras y no me... Read more

Incident date: Jan 1, 2026

Incident date: May 11, 2026

The engine failed. The car stopped completely with no warning. The same issue that other models are being recalled for turned out to be the problem with this engine. We had to have the engine replaced

Incident date: May 11, 2026

The contact owns a 2012 Ford Fusion. The contact stated that while driving at 40 mph, the steering wheel was hard to turn. The low tire pressure message was displayed. There was another unknown system message being displayed. The contact indicated the failure was related to NHTSA Campaign Number: 15... Read more

Incident date: Apr 27, 2026

I received a safety recall notice 26S28/NHTSA Recall 26V237 On the same day that this occurred in my truck. Luckily for me, I was within 2 miles of home, the only way I could get home was to drive in first gear up the mountain road to get there. My truck is not drivable. If this happens on a freeway... Read more

Incident date: May 6, 2026

The recall 25V-636 remains unresolved after more than 6 month passed since the manufacturer issued the campaign regarding the engine starter. I would like to see the NHTSA to put the manufacturer on notice that this is unacceptable. We cannot park the vehicle outside of structures permanently as th... Read more

Incident date: Feb 3, 2026

Complaint is related to NHTSA campaign number 17v-209, engine and engine coolant. The 2014 Ford Escape we purchased, leaked coolant into the cylinder. The cylinder head was sent to a machine shop, upon examination the cylinder head was cracked requiring an new cylinder head be installed. The work w... Read more

Incident date: Apr 6, 2026

The contact owns a 2021 Ram 1500. The contact stated that while driving at an undisclosed speed, the contact noticed an unusual popping sound. The low battery and check engine warning lights were illuminated. In addition, the battery lost power. The vehicle was driven to the shoulder of the road, an... Read more

Incident date: Mar 22, 2026

2/24/2026 Sitting at red light, very busy road, vehicle cut off and said push to start. Vehicle would not start and would not shift out of park to push out of road. Very dangerous to be stranded in moving traffic. Had to be towed to dealer and it's still there waiting on engine replacement.

Incident date: Mar 25, 2026

Incident date: Mar 18, 2026

Receiving Front Camera Malfunction Service required warning. Also receiving pre-collision assist, adaptive cruise control and automatic emergency break system warnings. Other systems likely disabled. Found that there was a TSB issued for the same year but on the F-150. DTC's C1001:31, U3000:89, U300... Read more

Incident date: Dec 31, 1969

ICCU failure within three (3) days of buying vehicle. Only 300 miles on it. Failed to charge with known working Level 1 charger on day 1, successfully charged with Level 3 charger on day 2, and then failed to charge at same Level 3 charger on day 3. Simply connecting the Level 3 charger on day 3 had... Read more

Incident date: Dec 31, 1969

Incident date: Mar 8, 2026

BPM warning in the KIA app. Apparently, ICCU and battery failures are t known issues with the KIA EV9s.

Incident date: Mar 8, 2026

There have been sudden downshifts occurring at any speed while driving. For example, downshifting from 6th gear to 1st gear while on the interstate driving around 70 mph. Or driving 40 mph on a public, decently popular road and having the downshift occur suddenly. Occurred 4 times in one day and alm... Read more

Incident date: Jan 4, 2026

I have had to put a new engine in my 2019 ford ecosport 3 times due to the open recall on the vehicle. It is currently at the ford dealership due to coolant leaking into the head gasket. The problems with the vehicle have been confirmed by the dealers. And no there were ZERO warnings or signs before... Read more

Incident date: Jan 20, 2026

Description of Incident: This is a recurring safety defect that has occurred multiple times from August 2023 to February 2026. The following description refers to the most severe incidents: 1. NATURE OF DEFECT: The vehicle experienced a sudden "Limp Mode" event where all dashboard warning lights ill... Read more

Incident date: Jan 20, 2026

The contact owns a 2020 Jeep Wrangler. The contact stated that upon starting the vehicle, the instrument cluster failed to operate as designed. The contact stated that the instrument cluster was black at start-up, preventing the gauges or safety features information from being displayed. The vehicle... Read more

Incident date: Dec 20, 2025

Our 2017 Acura MDX has developed a crank rod bearing knock. Fox Acura in Grand Rapids, Michigan, has advised that our vehicle’s VIN is not included in service bulletin 23 036 concerning connecting rod bearing failure, despite evidence that similar failures have occurred in Acura 3.5 liter engines ... Read more

Incident date: Dec 1, 2025

The contact owns a 2019 Chevrolet Silverado 1500. The contact stated that the vehicle was consuming an excessive amount of engine oil. The vehicle was taken to an independent mechanic, who informed the contact that similar vehicles were known for excessive oil consumption. The contact was adding oil... Read more

Incident date: Jan 1, 2026

The BECM (Battery Energy Control Module) failed. The vehicle illuminated the MIL and the driver display to show a "Reduced power". When restarted, the display showed "shift to park", which I did several times. After a couple of restarts it displayed the "Reduced power" message, but would not go i... Read more

Incident date: Dec 22, 2025

While driving, the vehicle intermittently loses engine power without warning. The loss of power occurs at normal driving speeds and during acceleration, creating an unsafe condition in traffic. When the issue occurs, the vehicle hesitates and fails to respond to throttle input, making it unsafe to m... Read more

Incident date: Dec 22, 2025

While driving on the interstate vehicle begin to surge and lag with a check engine light appearing. Vehicle never became disabled but after reading it sounds like this a very known issue with Trax’s. Chevy app stated it was the emissions control system which is most common for purge valve failure... Read more

Incident date: Dec 25, 2025

This vehicle had multiple issues as a 1 year old vehicle. Shaking in the front end on the highway, leading to replacing front sway bar and dampeners. Now multiple fire hazard recalls for the battery and for engine while driving, charging, and just being parked. The vehicle has shut off while driving... Read more

Incident date: Nov 15, 2025

The vehicle experiences throttle lag from stop or when rapidly accelerating from one speed to another(passing on highway or merging on interstate). Pushing on the gas pedal does not receive an immediate response from the engine. Issue comes up when accelerating from a stop sign or merging/overtaking... Read more

Incident date: Dec 19, 2025

The ICCU charge control unit for Kia electric vehicles that immediately depletes the 12v battery & significantly reduces motive power forcing you to pull over with no countdown to how long one has in terms of distance or duration. This uncertainty is absolutely unsafe as you cannot know how long it ... Read more

Incident date: Dec 15, 2025

Steering is slightly loose and thumps when turned to the right.

Incident date: Nov 29, 2025

Engine locked up while driving out of state on the interstate. Vehicle lost all power and engine stopped functioning. Managed to pull over and stop the vehicle on the side of the interstate. Had truck towed to repair shop where they diagnosed connecting rod/crankshaft bearing failure, as well as lif... Read more

Incident date: Nov 27, 2025

The contact owns a 2015 Jeep Grand Cherokee. The contact stated that while driving at an undisclosed speed with the heater engaged, there was an abnormal burning odor coming from the vehicle. The “Vehicle Temperature” and check engine warning lights were illuminated. The vehicle was taken back t... Read more

Incident date: Oct 10, 2025

I continually have the same issue with this vehicle. It started only a couple of months after initial purchase and has happened various times since. Today was one of those days it occurred, the ABS system will turn on along with the traction control light in the middle of the freeway causing the v... Read more

Incident date: Nov 20, 2024

Information/GPS system randomly goes completely blank/black. This possess a significant safety issue as it happens while driving in heavy city traffic where there is no way to stop and wait for the system to come back online. This has caused missed turns and the need to drive with no way of knowing ... Read more

Incident date: Sep 8, 2025

on 10/27/25 my son was driving car (2011 Mercury Milan) and light came on dash and car suddenly lost all power steering. Luckily car was able to be driven to side of the road when steering went out. I went to the Ford recalls website and it indicated "Epas steering efforts" was on the website as re... Read more

Incident date: Sep 26, 2025

Over-the-air firmware update that caused an in-motion shutdown while driving. various dash lights came on, shift to park indicator flashed, loss power, steering wheel stiffened up to the point it wouldn't move. There were no warnings before it went haywire. My family's safety was at risk as we were ... Read more

Incident date: Jun 7, 2024

On 3/19/2024 while pulling into my driveway towards my parking garage my car suddenly stalled wiht loss of power and wouldn't accelerate into the garage. The warning lights came on for EPC light. I looked for the code online and to my surprise I found Atlas has been plagued with several of such issu... Read more

Incident date: Sep 18, 2025

While driving, the vehicle suddenly shut down completely. All systems lost power: No lights Steering wheel locked/stuck Hazard lights were non-functional After approximately 2 minutes, the vehicle was able to restart, but an error message appeared: "ECU needs service" I then drove for about 2 ... Read more

Incident date: Sep 18, 2025

Can’t see to drive at night with low beams on. Miss turns at night.

Incident date: Oct 1, 2022

The contact owns a 2012 Hyundai Sonata. The contact received notification of NHTSA Campaign Number: 18V934000 (Engine, Fuel System, Gasoline). The contact stated that while driving 20 MPH, the vehicle stalled. There was an abnormal knocking sound coming from the vehicle. While driving at an undisclo... Read more

Incident date: Sep 8, 2025

The power steering turned off SUDDENLY twice, once on the highway at 60 miles per hour and the other time around a sharp turn of an exit ramp--EXTREMELY DANGEROUS

Incident date: Sep 8, 2025

White Diamond Pearl Paint started peeling prematurely approx 130,000 miles in 2023 in large sections causing unsightly paint. This is a very well known problem for this car in both Acuras and Hondas and a recall was done but with very very limited vehicles. Dealer refused to help us

Incident date: Sep 8, 2025

Incident date: Sep 15, 2025

The contact owns a 2019 GMC Sierra 1500. The contact stated that while driving on several occasions at undisclosed speeds, the engine was idling low, and the vehicle hesitated like it would stall. The contact stated that while stopped at a red light on several occasions, while the accelerator pedal ... Read more

Incident date: Sep 1, 2025

The contact owns a 2019 Kia Sorento. The contact stated that while driving at 70 MPH, there was an abnormal knocking sound coming from the vehicle. There was no warning light illuminated. The vehicle was taken to an independent mechanic, where an oil change was performed because the engine oil level... Read more

Showing 50 of 3,048 complaints.

NHTSA Safety Ratings, 2012 FORD FUSION

2012 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, 2012 FORD FUSION

84 manufacturer communications from 47 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
350000 EQUIPMENT	10
060000 ENGINE (PWS)	6
117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL	4
103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)	4
118000 ELECTRICAL SYSTEM:SOFTWARE	4
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	4
110000 ELECTRICAL SYSTEM	3
061000 ENGINE AND ENGINE COOLING:ENGINE	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

346000 COMMUNICATION:MANUFACTURER TELEMATICS

Various 2012-2015 vehicles equipped with a 3G modem may experience a lack of 3G modem performance. This may be due to the 3G cellular service functionality being decommissioned starting August 2021 and through March 2022. As the 3G cellular

980000 UNKNOWN OR OTHER

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

110000 ELECTRICAL SYSTEM

For Ford and Lincoln vehicles that require positive or negative battery terminal replacement, it is not necessary to replace the complete battery cable harness (14300 and 14301) for this concern. Positive battery cable clamp BT4Z-14450-AA a

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

350000 EQUIPMENT

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

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

060000 ENGINE (PWS)

TO HELP DIFFERENTIATE ENGINE OIL LEAKS FROM OTHER POSSIBLE SOURCES, A NEW WHITE-COLORED FLUORESCENT ENGINE OIL DYE IS AVAILABLE. WORKSHOP MANUAL (WSM), SECTION 303-00 HAS BEEN REVISED TO REFERENCE THE NEW WHITE-COLORED DYE. THE NEW WHITE FL

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

151300 SEAT BELTS:FRONT:RETRACTOR

Some vehicles may have a concern where the safety belt retractor webbing does not extract from the stowed position or exhibits excessive pressure on the occupant during use. This may be due to a normal condition which happens when the seatb

150000 SEAT BELTS

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

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

061000 ENGINE AND ENGINE COOLING:ENGINE

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

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

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)

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

060000 ENGINE AND ENGINE COOLING

350000 EQUIPMENT

Touchscreen navigation system - arabic language - blank screen

110000 ELECTRICAL SYSTEM

Some 2012-2016 vehicles equipped with a touchscreen navigation system and the language set to Arabic may exhibit a blank screen. This may be the result of the ribbon cables not being fully seated inside the front display interface module (F

353500 EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)

Touchscreen navigation system - arabic language - blank screen

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

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

SUMMARY TO BE PROVIDED ON A FUTURE DATE.

118000 ELECTRICAL SYSTEM:SOFTWARE

SUMMARY TO BE PROVIDED ON A FUTURE DATE.

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

118000 ELECTRICAL SYSTEM:SOFTWARE

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

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

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

117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

FORD: THE INSTRUMENT PANEL CLUSTER (IPC), ON SOME VEHICLES, FAILS TO OPERATE AT START UP AND NEEDS REPAIRING. MODEL 2012-2013 FOCUS. *PE

356000 EQUIPMENT ADAPTIVE/MOBILITY

FORD:LINCOLN: ON SOME VEHICLES, THERE ARE VARIOUS RELATED CONCERNS ABOUT THE SYNC FEATURES, SUCH AS SYNC FEATURES INOPERATIVE, LACK OF OR SLOW RESPONSE TO PHONE AND VOICE BUTTON OPERATION. MODELS 2012-2013 FOCUS, E-SERIES, EDGE, EXPEDITIO

353000 EQUIPMENT:ELECTRICAL

350000 EQUIPMENT

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/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

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

FORD: AWF21 AISIN 6 SPEED TRANSMISSION BUILT ON OR BETWEEN 8/22/2011 AND 12/05/2011 -UNIQUE TCM PART- SERVICE INFORMATION. *JS

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/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

010000 STEERING

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

021530 SUSPENSION:FRONT:CONTROL ARM:LOWER ARM

117000 ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

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 (current)	6	3,048
2011	9	3,651	View
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

2012 FORD FUSION

Complaint Statistics

Top Reported Components

NHTSA Safety Ratings, 2012 FORD FUSION

Safety Technology

Technical Service Bulletins, 2012 FORD FUSION

Most Affected Components

NHTSA Safety Investigations, FORD FUSION

FORD FUSION - All Years Overview

FORD FUSION - Year by Year

Other FORD Models