NHTSA (USA)Critical
At a glance
What can fail
The driver's side air bag inflator may explode. This can happen when the propellant degrades after prolonged exposure to high heat, humidity, and temperature changes.
What the fix does
This page covers 5 recalls, 2593 owner complaints, NHTSA crash-test ratings and EPA fuel economy for the 2012 Ford Fusion.
19–38 mpg combined
6.2–12.4 L/100km
Midsize Cars
Fuel economy data from fueleconomy.gov (EPA / U.S. Dept. of Energy). Annual cost based on 15,000 mi/yr at 55% city driving and current fuel prices. MPG is U.S. gallons; L/100km converted. Ranges reflect the 6 tested variants for this model year.
4/5 Overall
NHTSA 5-Star Safety Rating
Steering complaints dominate the 2012 Ford Fusion's complaint record by a wide margin. Owners consistently report sudden, complete loss of electric power steering, often accompanied by a "Power Steering Assist Fault" warning on the dash. When it happens, the steering wheel becomes extremely heavy and difficult to turn, sometimes requiring both hands and significant physical effort. Some owners report the warning light never illuminated before the failure, while others say the system failed repeatedly even after a dealer visit. Rack-and-pinion failure and the power steering control module are the components most frequently mentioned in these reports. Airbag-related complaints are the second-most-reported category, though at considerably lower volume than steering. A small number of owners also report powertrain issues. Among the non-steering reports, one recurring detail involves driver-side doors unexpectedly opening while the vehicle is in motion, with the door-ajar warning light illuminating afterward.
2,593
Total Complaints
111
Crash-Related
9
Fire-Related
45
With Injuries
By System
The 2012 Ford Fusion has 5 recalls, the most serious being a Takata airbag defect affecting both the driver and passenger frontal airbags, where the inflator can rupture and send metal fragments into the cabin, causing serious injury or death.
Both airbag inflators are covered by this issue, and prior repair attempts did not fully resolve it for all affected vehicles. The passenger-side inflator risk is elevated for vehicles that were ever registered or sold in high-humidity regions including Florida, Texas, Hawaii, and several U.S. territories, where heat and moisture accelerate the degradation that leads to rupture. The driver-side inflator carries the same fragmentation risk across a broader range of vehicles.
The remaining recall covers the electric power steering system on Fusion models without the 3.5L engine. The power steering assist can cut out unexpectedly, requiring significantly more effort to steer, particularly at low speeds where the loss is most noticeable and a crash becomes more likely.
At a glance
What can fail
The driver's side air bag inflator may explode. This can happen when the propellant degrades after prolonged exposure to high heat, humidity, and temperature changes.
What the fix does
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Ratings from NHTSA's New Car Assessment Program (NCAP). Based on 2 tested variants; worst-case ratings shown.
Complaints are owner-reported and reflect individual experiences, not confirmed defects. They are distinct from recalls. Data sourced from the national vehicle safety complaint database. See trending complaints →
Dealers will replace the driver-side airbag inflator or module with a new one at no cost to you.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The driver or passenger front air bag inflator may explode due to propellant breakdown after prolonged exposure to high humidity, heat, and temperature changes.
What the fix does
Dealers will inspect the air bag module and replace the module or inflator if needed, at no cost.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The passenger front air bag inflator may explode due to propellant breaking down after prolonged exposure to humidity, heat, and temperature changes.
What the fix does
Dealers will replace the passenger front air bag inflator at no cost to you.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The passenger front air bag inflator may rupture during a crash due to propellant breakdown from long-term exposure to humidity and temperature changes.
What the fix does
Dealers will replace the passenger front air bag inflator at no cost. Ford will mail recall notices and notify owners when parts are available.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The electric power steering assist system may shut down due to a steering motor sensor fault, potentially eliminating power steering.
What the fix does
Dealers will check the steering control module for fault codes. If found, the steering gear is replaced. If none are found, the steering control module software is updated.
Summarized — see the official notice for exact wording, dates, and contacts.