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 7 recalls, 186 owner complaints, NHTSA crash-test ratings and EPA fuel economy for the 2011 Mercury Milan.
24–38 mpg combined
6.2–9.8 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 3 tested variants for this model year.
4/5 Overall
NHTSA 5-Star Safety Rating
Steering is the clear standout for the 2011 Mercury Milan, accounting by far the largest share of owner complaints. Owners consistently report the electric power steering failing outright, often with a "Service Power Steering Now" warning appearing on the dash just before assist cuts out, leaving the wheel extremely heavy and difficult to turn. This pattern shows up across a wide range of mileages. Exterior lighting draws the second-highest complaint volume, with owners reporting failures in the LED brake light assemblies, a particular frustration because the part has been discontinued, making replacement difficult to source. The powertrain category rounds out the top three, with a smaller cluster of owners describing issues including loss of reverse gear, where the engine revs normally but the vehicle won't move when shifted into reverse. The brake light assembly discontinuation issue centers on the passenger-side unit, part number 9N7Z 13404 A.
186
Total Complaints
1
Crash-Related
2
Fire-Related
By System
The 2011 Mercury Milan has 7 recalls, the most serious being Takata airbag inflators on both the driver and passenger sides that can explode and send metal fragments into the cabin, causing serious injury or death.
The airbag concern spans multiple filings but represents the same defect: propellant inside the inflators can degrade over time, particularly in hot and humid climates, making an explosion more likely during a crash. Prior repair attempts have not fully resolved the issue for all affected vehicles, which is why several campaigns exist. On the fuel system side, the vapor canister's purge valve can fail to regulate pressure properly, causing the fuel tank to crack and leak, which raises the risk of a fire near any ignition source. There is also a wheel stud concern on vehicles equipped with 17-inch steel wheels, where the studs can fracture and lead to a wheel separating from the vehicle while driving. Lastly, the electric power steering system can lose its power assist unexpectedly, requiring significantly more effort to steer, especially at low speeds.
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 once parts become available.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The fuel vapor canister's purge valve may not work correctly, causing abnormal pressure changes inside the fuel tank.
What the fix does
Dealers will update the engine control software, test the purge valve, inspect the fuel tank for cracks, and replace parts as needed.
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.
At a glance
What can fail
Wheel studs on certain 2010-2011 Fusion and Milan models may fracture, which could cause a wheel to separate from the vehicle.
What the fix does
Dealers will inspect and replace rear brake discs if needed, and replace wheel lug nuts on all four wheels.
Summarized — see the official notice for exact wording, dates, and contacts.