Summary
The Ford Fusion has 30 recalls spanning 2010 through 2020, with the most serious recent issue affecting 2019-2020 Fusion Energi plug-in hybrid models, where the battery energy control module can sustain damage from excess voltage, resulting in sudden loss of drive power or a fire that can occur even while the vehicle is parked.
On the 2017 model year, left rear seat back pivot pins may have inadequate welds, allowing luggage to break through into the passenger compartment in a crash. A separate 2017 recall covers LED headlamp support brackets that can shift the daytime running light guide out of position.
The 2016 model has two issues: door latches on vehicles operated in warm-climate states can crack from heat exposure and allow doors to open while driving, and a small production window of 2016 models has a driver seat track rear riser that was improperly welded and may not hold the driver in place during a crash. The 2013-2016 model years share a seatbelt recall where the front pretensioner anchor cable can weaken from heat generated during pretensioner deployment in a crash, reducing the belt's ability to restrain the occupant. On 2013-2016 vehicles equipped with 2.5-liter and six-speed automatic transmissions, a shifter cable bushing can degrade and detach, allowing the transmission to be in a different gear than the shifter indicates and creating a rollaway risk.
On 2014-2015 models, the ignition key can be removed when the transmission is not actually in Park, and a brake pedal bumper in vehicles sold in certain southern states can separate, causing brake lights to stay on and confuse other drivers. The 2013 model year carries the heaviest recall load: the steering gear may be missing an internal retaining clip or assembled incorrectly, either of which can cause sudden loss of steering; the 1.6L engine can crack its cylinder head if run low on coolant, leaking oil onto hot components and starting a fire; the clutch on 1.0L and 1.6L manual-transmission cars can wear prematurely; the electric power steering motor bolts can corrode and break on vehicles in heavy salt-use regions, causing a sudden increase in steering effort; and low-beam headlamp coatings on early 2013 production can haze over time and reduce road illumination.
The 2012-2015 Fusion Energi 120V charge cord can overheat and start a fire. Going back to the 2010 model year, the canister purge valve can cause pressure buildup that cracks the metal fuel tank, and 17-inch steel wheels can lose clamping force at the wheel studs, eventually allowing a wheel to separate from the vehicle.
