2012 FORD FUSION

6 recalls, 3,058 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

3,058 total complaints 165 crashes 20 fires 107 injuries 8 deaths

Top Reported Components

Component	Complaints
STEERING	1,176
AIR BAGS	411
POWER TRAIN	182
ELECTRICAL SYSTEM	174
ENGINE	173
UNKNOWN OR OTHER	157
SERVICE BRAKES	103
VEHICLE SPEED CONTROL	91
ELECTRONIC STABILITY CONTROL (ESC)	80
STRUCTURE:BODY	80

Incident date: Sep 6, 2026

I got a 2012 ford fusion se 2.5 4l power steering gone out in it,I put in the vin number to see if mine was recalled it said 0 but my car has the part in the car that made the car recalled ,on the dash its says power steering service its dangerous and I had my child in the car vin number on my car i... Read more

Incident date: Aug 3, 2026

While I was driving my 2012 Ford Fusion on August 3rd the steering cut out. I parked the car and re-started it and it worked again. It went to the shop (Extra Mile Automotive) on XXX where they informed me of the 2015 recall on the steering. Recall number 15S18 and program 15N01 When I spoke with ... Read more

Incident date: Aug 3, 2026

Incident date: Jun 1, 2025

Vehicle experienced loss of power steering so it was hard to steer.When I called a ford dealership I was told my vehicle didn’t qualify for any power steering recalls so I would have to pay full price which is unaffordable

Incident date: Feb 6, 2026

While driving my 2022 Hyundai Tucson Hybrid, the vehicle suddenly lost power, began shaking, and all warning lights illuminated at once. The car would not accelerate properly and became unsafe to operate in traffic. After pulling over and restarting the vehicle, the warnings cleared, but the issue h... Read more

Incident date: Aug 17, 2023

The vehicle's Auto-Idle Stop (AIS) feature is defective and creates a severe safety hazard. While stopped at a busy road intersection, the feature engaged and shut the engine off normally. However, when releasing the brake pedal to proceed, the engine glitched and completely failed to restart, leavi... Read more

Incident date: Jul 27, 2026

Subject: Vehicle Safety Incident Report – Fuel Pump Disconnection and Oil Leak To: National Highway Traffic Safety Administration Date: July 27, 2026 I am submitting this report to detail a recent vehicle malfunction that posed significant risks to my safety and that of others on the road. Whi... Read more

Incident date: May 27, 2026

While i was driving 65 MPH on the highway with several car length ahead of me I gently tried slowing down and the car jammed on the brakes forcefully causing my husband and I to be jolted forward and seatbelts locked. Thankfully, the person behind me did not hit me. This is a recall that was suppose... Read more

Incident date: Jul 19, 2026

I was run off the road by a drunk driver I hit a tree at 35MPH MY AIR BAGS DID NOT DEPLOY NOR DID MY SEAT BELT LOCK!!!! I NOW HAVE MULTIPLE INJURIES I HAVE BROKEN BONES ALL THROUGHOUT MY FACE!!!!! A SEVERE CONCUSSION!!!!! Any time I call the the customer care center and try and get information or ca... Read more

Crash 1 injured

Incident date: Jul 10, 2026

I was driving on the interstate and the tread just separated from the sidewalks. 235/65R17. I didn’t hit anything. There was no damage to the tire. It just disintegrated.

Incident date: Jun 22, 2026

Visible wiring has become exposed in the windshield/A-pillar area. There is no airbag/SRS warning light at this time, and I am not able to determine from visual inspection whether the exposed wiring is related to the restraint system. However, this is a safety-sensitive area because it can contain o... Read more

Incident date: Jun 28, 2026

See attached document for complaint.

Incident date: Jun 18, 2026

What's malfunctioning: coolant monitoring system shows low coolant warning when coolant level is observably fine. Problem has been ongoing for over a year. Available for inspection: yes. Safety problem: coolant monitoring is inaccurate, causing alarm when coolant levels are fine and possibly causi... Read more

Incident date: May 30, 2026

Bought car on a Saturday (6-20-26)and that night noticed the drive mode was broke and the forward Collison is broke and will go on and off. Dealership said they did the whole inspection on the car before they put it on the lot to sell. Also, oil was extremely low when I left the lot and had to go ba... Read more

Incident date: Sep 8, 2025

The contact’s wife owned a 2022 Tesla Y. The contact stated that while the vehicle was parked, his wife shifted the gear shifter into drive(D), and the vehicle independently accelerated. The Autonomous feature was not engaged. The brake pedal was depressed; however, the vehicle failed to respond a... Read more

Crash 1 injured

Incident date: Sep 8, 2025

Crash 1 injured

Incident date: Sep 8, 2025

Crash 1 injured

Incident date: Jan 1, 2026

We were traveling to our son’s college graduation, driving on a rural interstate and suddenly all of the vehicle’s warning lights lit on the dash and the car started losing, and then completely lost power. The car was no longer operational. We were stranded on the roadside of a remote but busy 2... Read more

Incident date: Jan 1, 2026

The issue involves the second and third-row power folding seat control system in my 2026 Hyundai Palisade Calligraphy Hybrid following Recall 296. Before the recall update, the vehicle included driver-controlled power folding seat functions through infotainment screen controls and one-touch seat fo... Read more

Incident date: Jan 1, 2026

At 116 miles, the engine blew and I was informed it would need to be replaced. I purchased a used engine from the same year of vehicle because Kia said it would not be covered since the vehicle had passed the 100,000 mile mark. I spend over $5,000 to get this engine and have it installed by a licens... Read more

Incident date: May 11, 2026

While driving my LKAS, ABS, and Lane assist lights will come on intermittently. When this happens I am not able to use cruise control. I have noticed that my vehicle has an issue accelerating before the lights come on. This is putting the safety of me and passengers at risk. The dealership has not b... Read more

Incident date: May 11, 2026

I am filing this complaint regarding a premature material failure on my 2024 Toyota Tundra. The factory-applied smoked overlay finish on the front grille is peeling and separating in large chunks, exposing the chrome underneath. This is occurring at approximately 46,000 miles and less than two years... Read more

Incident date: Apr 27, 2026

The contact owns a 2010 Toyota Camry. The contact stated that upon taking the vehicle out of the garage and driving the vehicle, the contact later noticed that the dashboard was melting and was sticky, causing a reflection on the windshield and a glare. The vehicle was taken to an independent mechan... Read more

Incident date: May 6, 2026

I am submitting this complaint regarding my 2015 Dodge Dart SXT with an active safety recall that currently has no available remedy. My vehicle experienced failure related to the recall issue, resulting in the vehicle becoming inoperable and requiring repair. At the time of failure, I was informed ... 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: Feb 3, 2026

I am reporting a recurring defect involving the sunroof drain system in my 2023 Nissan Pathfinder Platinum that has caused multiple interior flooding incidents. The vehicle has flooded three separate times due to failure of the sunroof drainage system. Water enters the cabin during rain events and ... Read more

Incident date: Mar 22, 2026

Significant issues with adaptive headlights having a large shadow in middle of beam as well as two smaller dark shadows at end of beam that are very distracting. It also dims very low at times severely reducing my visibility especially at different grades of the road. The headlights were so bad from... Read more

Incident date: Mar 25, 2026

After we had our car serviced for the two recalls on the car, all of the check engine lights came back on again a little over one week later. We took it back to the dealership today and were told the fuel injectors need to be replaced, and they said this is a "common problem." We have been researc... Read more

Incident date: Mar 18, 2026

The recall is still not fixed and dealership has my van for over 3 months now. I haven't even had my van a year.

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

The rear view camera doesn't work keeps going blank or screen is blurred or stays on while driving forward. screen won't connect to phone or screen stays on when vehical is shut off. When starting vehical it only shows ford emblem and won't load at all. Not able to change anything on it at all for m... Read more

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: 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

HVAC system failure in sub-freezing weather causing loss of windshield defrost and cabin heat. Tesla has acknowledged this as a known hardware design limitation of the heat pump/octovalve system but is refusing repair coverage outside of warranty. This condition affects driver visibility and winter ... Read more

Incident date: Dec 20, 2025

Horns assemblies are Failing repeatedly. Since ownership of the vehicle (2023 and a CPO Platinum Wrap), I have had to replace a single horn, or both horns three times with local Hyundai dealerships. mostly the right horn would fail, then the left. I am currently making efforts to have my vehicle’s... Read more

Incident date: Dec 1, 2025

Intermittent Transmission issue. Truck will not shift into 5th or 6th gear. Temporary fix is turning the car off and on again. Problem will eventually return. Is this a Software or Hardware issue? Is there a campaign or recall on this issue?

Incident date: Jan 1, 2026

After driving car a few minutes with the heated seats “on”, the driver’s seat became extremely hot. Driver burned finger upon checking the seat and a hole was burned through the seat upholstery. No warning lamps or messages appeared. We were concerned for further overheating or possible fire... 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

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

my abs and traction control light is on, took it in and got the recall done at slimans in amhust ohio, light is still on. they want $300 to test it further. i have seen several posts about the control module failing. i took it in to another garage, they replaced the rear sensor. still didnt fix the... Read more

Incident date: Dec 19, 2025

Multiple times when there is a car on my left or right blind spot and I am merging into their lane the warning does not go off and has caused me to nearly collide with the cars without my intervention. The warnings only work if the cars are behind me not adjacently. This is misleading because the , ... Read more

Incident date: Dec 15, 2025

The contact owns a 2017 Jeep Cherokee. The contact received notification of NHTSA Campaign Number: 25V011000 (Power Train); however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The co... Read more

Incident date: Nov 29, 2025

The contact owns a 2025 Mazda CX-5. The contact stated while driving at various speeds, the passenger's side-view mirror blind spot detection system sensor was detecting vehicles intermittently. The contact stated that the passenger's side-view mirror blind spot detection system sensor detected vehi... 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

TIMING BELT TENSIONER - started leaking at only 31K miles. Honda has denied the request to fix this for free of cost. Dealer is demanding $2000 to replace the 6 Cyl Timing Belt Package. Per the link below, this is a common issue with Honda cars (94,000 card recalled so far): [XXX] . I am [XXX] wit... Read more

Incident date: Nov 20, 2024

My vehicle, a 2017 Lexus RX 350 with approximately 111,872 miles, experienced a near-total failure of the infotainment/navigation screen approximately five months ago (around June 2025). The system would only display the introductory safety message, backup camera feed, a single radio station, and ba... Read more

Incident date: Sep 8, 2025

Driving on loop 20 overpass on Hwy 59 in Laredo Texas suddenly the engine lost power and started to skip and miss fire while a loud tapping noise was generated, due to the loss of power and skipping, alarms showed in the main console requiring immediate service to the engine, traction and braking sy... Read more

Showing 50 of 3,058 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

28,786 Total Complaints

11 Investigations

1,214 Reported Crashes

304 Reported Fires

22 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	262	View
2019	3	410	View
2018	2	578	View
2017	4	1,391	View
2016	13	2,083	View
2015	13	1,282	View
2014	19	1,766	View
2013	19	2,375	View
2012 (current)	6	3,058
2011	9	3,656	View
2010	13	7,026	View
2009	7	1,169	View
2008	6	1,533	View
2007	5	1,277	View
2006	5	920	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