Ford Fusion Recalls

The Ford Fusion has 57 recalls spanning the 2006–2020 production run; the most serious recent issue affects 2019–2020 Fusion Energi plug-in hybrid models, where the high-voltage battery energy control module can overheat and start a fire even while the vehicle is parked and off, or fail suddenly and cut drive power while moving.

The 2019–2020 model years also have a recall covering the engine block heater, which can crack, leak coolant, and short circuit when plugged in, raising fire risk. On 2019–2020 models, the rearview camera can display a blank image when backing up.

Going back to 2017, the torque converter on 2.0L automatic-transmission models can lose its weld connection to the engine, leaving the car unable to move. A rear seat back pivot pin weld on some 2017 models can fail in a crash and allow cargo to fly forward into the passenger compartment.

The 2013–2018 years carry a high concentration of recalls. Front brake hoses on 2013–2018 vehicles can rupture and leak fluid, lengthening stopping distances. On 2014–2018 models, the steering wheel retaining bolt can loosen and let the steering wheel detach while driving. The electric power steering motor mounting bolts on 2013–2016 models registered in salt-belt regions can corrode and break, causing a sudden loss of power assist. The transmission shift cable bushing on 2013–2016 models can degrade and detach, leaving the transmission in a different gear than the shifter indicates and allowing the car to roll away when the driver believes it is in Park. On 2013–2014 models equipped with a 1.6L engine, a low coolant level can cause the cylinder head to overheat, crack, and leak oil onto hot exhaust components, creating a fire risk. A related manual transmission recall on 2013–2014 models with that same engine covers a clutch that can fracture and leak transmission fluid near ignition sources. Front seatbelt pretensioner heat on 2013–2016 models can weaken the anchor cable and prevent the belt from properly restraining an occupant in a crash. Door latches on 2013–2014 models were subject to multiple rounds of recalls for a broken pawl spring that allows a door to appear closed but open while driving; a prior repair attempt on 2013–2014 vehicles did not fully resolve the issue, prompting an additional recall. A 2016 model year fuel tank recall covers units with insufficient wall thickness that can crack and leak fuel.

The Takata airbag inflator defect runs across the widest year range of any issue in this history. Driver and passenger airbag inflators on 2006–2012 models can rupture and send metal fragments into the cabin in a crash. Earlier 2006–2010 models have an anti-lock brake hydraulic control unit whose valves can react with certain brake fluid additives, fail to close fully, and require extra pedal travel to stop the vehicle. The 2010–2011 model years have a fuel vapor canister purge valve that can cause abnormal pressure buildup and crack the fuel tank, leading to a fuel leak. A 2010 model year recall covers 17-inch steel wheels where wheel stud failure can cause a wheel to separate from the car entirely.