Ford Fusion
Reliability, NHTSA Complaints & Recall History

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

Safety Recall

2020 Ford Fusion 1.5L EcoBoost engine completely failed. Ford dealership diagnosed need for complete engine and turbo replacement at $13,475. Believed to be related to known EcoBoost coolant intrusion defect.

Coolant problems and cylinder damage on engine due to coolant intrusion. Ford has not issued a recall on this well known problem and issue on ALL Ford Fusion Models. Several complaints have been made by many Ford Fusion owners for putting drivers and vehicle owners at risk of driving unsafe vehicles and poor driving conditions.

While turning into a parking lot the lower control arm snapped (broke in half, approximately). The picture I sent is of a front lower control arm, however it is not a picture of the actual control arm that broke. After it broke, the car was forced into a sharp left turn, resulting in the car crashing into a telephone pole. The pole was not damaged but there was damage to the car.

The contact owns a 2020 Ford Fusion. The contact stated that upon rolling to a stop, the vehicle started shuddering while depressing the brake pedal. The contact stated that the message "Transmission Not in Park" was displayed. The gear shifter then unexpectedly shifted to several positions independently. The contact discovered a YouTube video that assisted with correcting the issue. The contact used a screwdriver to manually shift the gear shifter back to park(P). The contact was forced to maneuver the shifter back and forth until the gear shifter engaged and resumed normal operation. The contact stated while his wife was driving the vehicle on one occasion, the failure recurred, and the driver was forced to tow the vehicle to a local dealer. Upon investigation, the contact discovered NHTSA Campaign Number: 22V413000 (Power Train) and associated the failure with the recall. The manufacturer was notified of the failure and informed the contact that the vehicle was not included in the recall. The contact was provided a case number. The vehicle was not diagnosed or repaired and remained with the dealer. The failure mileage was approximately 150,000.

I don't know if this qualifies as an immediate safety issue, however, if the vehicle is stopped and placed into park on a busy freeway, or in traffic in any way, then this absolutely is a safety issue after the fact because the vehicle cannot be moved due to not being able to get it into gear. This involves the shift linkage component and not being able to get the car out of park and into any other gear. It's already an active recall but it's VIN specific and my VIN was not included. It really needs to be though. It should be all Fusions at this point. I drive a 2020 Ford Fusion and the shift linkage bushing broke. Initially I got the "shift system error" message back in January and could not get my car into gear. It would just bounce right back into park. I had to call a tow truck but eventually the driver was able to somehow reset the system using the hidden reset button in the center console. It was enough to keep me running for a couple of months. However, two weeks ago it happened again and the reset option was no longer working. The car was towed to my dealership and they replaced the "missing" bushing and I was charged $511.00 for the repairs. Considering how widespread this issue this seems to be, I would like to see a full model-specific recall issued for these Fusions and possibly reimbursement for the costs I was subjected to due to the issue. I can provide the service receipts from the dealership showing that it was replaced and the total cost. Thank you!

Automatic transmission failed No warning No smells no shaking no jerking no light on dash board until it went out that's when it jerk and still no check engine light just a wrench that popped up once

HEAD GASKET FAILING, common problem in car. Broke down in the middle of busy Main Street and started smoking out of exhaust pipes. It has been confirmed by my service center that they now have 3 ford fusions, including mine, that they are replacing a head gasket on right now. They were no warning signs, it happened out of nowhere.

I am reporting a life-threatening incident involving my 2020 Ford Fusion PHEV. On December 5, 2025, while my wife was driving on a public street, the vehicle suffered a sudden, complete engine failure followed by smoke and fire originating from the high-voltage battery pack in the trunk. There were no prior warning signs or dashboard alerts before the incident. This vehicle was sold via IAAI auction in September 2023 without disclosing the active, critical safety recall (NHTSA 23V440 / Ford 23S33) issued in June 2023. This non-disclosure placed my family in extreme danger. When the fire started, my wife was in a state of panic. I arrived at the scene before emergency services. Being a technician, I performed a high-risk manual extraction of the burning battery pack to prevent the entire vehicle and the surrounding residential area from a potential explosion. I risked electrocution and toxic chemical exposure to save lives. The damaged battery pack is currently preserved and available for professional inspection upon request. As a result of the fire and exposure to extinguisher chemicals, I suffered respiratory distress and asthma-like symptoms for several days. I have contacted Ford Motor Company through official channels and documented all interactions. Ford representatives stated that they 'only assist customers in the United States' and local representatives in [XXX] have officially refused to provide the remedy, stating they are not authorized or equipped for this specific recall. I am now left with a charred, unusable vehicle. I demand a full investigation into the failure of the recall remedy process and manufacturer liability for these life-threatening damages. ( Form fields about my location are place holders. Contact me in [XXX] (Country) at [XXX] / [XXX] ]. I hope you do don't ignore our lives due to geography. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

purge solenoid unplugged, several times for years, which causes the vehicle not to start up after getting fuel. Check engine light come on often due to this. When I bring vehicle to Mecanic shop they plug it right back. P0443 evap purge control valve “a” circuit

Shifter Cable broke in multiple vehicles of the same year make and model in our fleet of vehicles within a short amount of time. Car would not change gears properly. Issue confirmed and fixed by a local mechanic shop. No warning messages or other symptoms prior to failure.

Multiple vehicles of the same year make and model had the shifter cable fail within a short amount of time. car would not change gears properly. problem confirmed and fixed by local mechanic shop. no inspections. no warning lights or messages prior to failure.

I have a check engine light on due to an issue in the emissions system. The issue is that the purge valve is stuck open. I know that this is an issue that you had a recall on for older models of the ford focus for this same reason. All the systems of a stuck purge valve are the issues I am having with the vehicle.

I keep getting SHIFT SYS FAULT error. My car will not move out of P (park). I towed my car to repair shop on 2/11/2026 - 02/13/2026 the mechanic told me he replaced the bushing kit and the gear dial. Less than a week later on 02/26/2026 I got the same error and was able to drive my car to Village Ford Dealership (my car is still there) I was told on Monday that the technicians thought they fixed the issue but the same thing happen and now they are unable to get the car out of P (park) and that the technicians would have contact FORD HOTLINE because the repairs are not working. The issue was once recalled on older Ford fusions but according to google 2020 fusions have reported the same issue.

I only have about 45K miles on my car. I began to hear a rattling sound while vehicle is idling and more pronounced with the air conditioning on. I took it to the Ford service department at the dealership where I bought it and was told it was a cracked engine flex plate and it would be a $3000 cost to repair. I was extremely surprised at such an expensive fix for such low mileage and looking online I found a Ford customer satisfaction program 22N12 for this exact issue. I checked and my car was indeed manufactured at the plant in Hermosillo, MX covered in the program. However I was told that I am not covered because it is for the 2.0L engine and not the 1.5L engine. It seems to be more than a coincidence that I would have this issue on this model of car from this manufacturing plant. There were no warning lights of any kind that went off. I have seen that this could have been a major issue had it went unrepaired and caused a major safety issue. I am unfortunately being forced to pay for this out of pocket on such a new car but also this issue is clearly not only on the 2.0L vehicles and the recall/customer satisfaction program should be expanded to include 1.5L

"The incident occurred immediately after shifting the vehicle into reverse and starting to move. The engine suddenly shut down with a 'System Performance' alert, and cooling fans engaged at maximum speed. Moments later, a thermal runaway event began in the high-voltage Li-ion battery pack, leading to a catastrophic fire. This is directly related to Recall 23V440 / 23S33 (BECM failure). The fire was extinguished by the local fire department in Telavi, Georgia (Country)."

COMPONENT: ELECTRICAL SYSTEM, ENGINE I HAVE HAD THIS SENSOR THAT MAKES MY CHECK ENGINE LIGHT STAY ON 3 SEPARATE TIMES! THIS NEEDS TO BE RE CALLED I SEE MULTIPLE COMPLAINTS WITH THE SAME CONCERN

The locking mechanism that keeps the seat belt safely locked into place is malfunctioning. I have to ensure the belt is firmly in place and will not tug out of the lock before going anywhere. The seatbelt will not lock in place properly.

Last month, while transporting my brother to his arm surgery in Chapel Hill, NC, I observed unusual and audible shifting behavior when engaging the vehicle's sport mode. This mode is typically utilized for extended journeys on highways and interstates. Although the anomaly was brief, I did not initially consider it significant. Several weeks later, upon departing from my community college campus, I encountered a red light near Santa Fe Drive. The vehicle exhibited a hesitant and labored acceleration, eventually moving forward. This incident was particularly concerning given the high volume of traffic during that time of day. I subsequently stopped at a nearby 7-Eleven for fuel, suspecting a low fuel level might be the cause. No engine warning lights or mechanical indicators were illuminated, and the oil life was at 70% with appropriate oil levels. Fast forward to the last week of January. On Wednesday the 28th, I began to notice recurring shifting issues with the vehicle during a class break. Additionally, engaging reverse consistently resulted in a harsh shift. As I was leaving my neighborhood to return to class, the vehicle completely failed to engage gears or accelerate. At this point, both the wrench and check engine warning lights illuminated. Upon returning home, I utilized the code reader provided by my mother last Christmas, which displayed the code "P0772." This confirmed my prior research regarding potential issues with the EcoBoost engine. I am relieved that this mechanical failure did not occur amidst the heavy traffic typically found on 210 Murchison South , I-295, Bragg Blvd Fayetteville/Spring Lake and other routes heavily trafficked due to the military base. The high speeds on these roads could have led to a dangerous situation, potentially causing a rear-end accident or other involving other drivers who may be speeding or inattentive. I am grateful that I did not experience a stall in the middle of traffic, which could have compromised my safety.

Back up camera, and touch screen go completely out...the whole system will not come back on until vehicle is shut off and restarted. This has happened multiple times now.

In 2024 on Black Friday while driving home from work my car all of a sudden was starting to lose speed. Even when I'm hitting the gas it would not accelerate and I could push it all the way down to the floor or nothing. And all of a sudden I start to see a whole bunch of monitors go off on my dashboard animal League to the government off and then all of a sudden I started see this underneath my core board pulled over and all sudden those planes coming from my engine and within minutes the whole car was destroyed. Fire department came to drop the fire and everything but the trunk was left essentially. The insurance company has taken to car since and I believed it was sold for parts. I have Thought I had submitted this before but never got somebody you can just in case I messed up. I just feel like a car shouldn't just randomly catch fire