NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
30 reportsClear category filter59,000 miles · Apr 10, 2017
Electrical System
TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. WHILE THE CONTACT'S WIFE WAS DRIVING, THE VEHICLE STALLED. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT A FRACTURED WIRE IN THE HIGH VOLTAGE CABLE FOR THE HYBRID HARNESS KIT NEEDED TO BE REPAIRED. THE VEHICLE WAS REPAIR…
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TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. WHILE THE CONTACT'S WIFE WAS DRIVING, THE VEHICLE STALLED. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT A FRACTURED WIRE IN THE HIGH VOLTAGE CABLE FOR THE HYBRID HARNESS KIT NEEDED TO BE REPAIRED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 59,000.
NHTSA ODI #10971697
52,000 miles · Feb 22, 2017
Electrical System
THE CAR HAS STALLED MORE THAN 20 TIMES. NO WARNINGS TO PULL OVER JUST A ENGINE CUT OFF. THIS WHILE DRIVING AT 30 MILES A HOUR, BACKING UP, TURNING, ACCELERATION. SOMETIME TAKING 4 OR 5 MORE TIMES TO RESTART. THE ONLY CODE FOUND STATED THAT THE DRIVE TRAIN WAS FAULTY. HAVE RETURNED THE CAR TO THE DEALERSHIP 3 TIMES. FIRST T…
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THE CAR HAS STALLED MORE THAN 20 TIMES. NO WARNINGS TO PULL OVER JUST A ENGINE CUT OFF. THIS WHILE DRIVING AT 30 MILES A HOUR, BACKING UP, TURNING, ACCELERATION. SOMETIME TAKING 4 OR 5 MORE TIMES TO RESTART. THE ONLY CODE FOUND STATED THAT THE DRIVE TRAIN WAS FAULTY. HAVE RETURNED THE CAR TO THE DEALERSHIP 3 TIMES. FIRST THEY THOUGHT IT WAS THE BATTERY. CAR STALLED LESS AN A MILE AWAY FROM THE SHOP. THEY HAVE NOW HAD THE CAR FOR 2 FULL DAYS AND CAN NOT FIGURE OUT WHAT IS WRONG WITH IT. THIS IS A SAFETY ISSUE SINCE I DON'T KNOW WHEN OR WHERE IT WILL STALL OUT.
NHTSA ODI #10956405
115,000 miles · Jan 27, 2017
Electrical SystemSteering
POWER STEERING STOPPED WORKING WHILE MAKING A TURN ON THE HIGHWAY. WAS ABLE TO AVOID ACCIDENT WITH THE CAR BESIDE ME BUT WAS VERY DIFFICULT TO STEER THE CAR IN THE DIRECTION NEEDED. CAR CODE CAME UP TO "SERVICE POWER STEERING IMMEDIATELY". VERY DANGEROUS SITUATION IF NOT PREPARED WHEN THIS HAPPENS!
NHTSA ODI #10947936
56,000 miles · Oct 29, 2016
Electrical SystemService Brakes
THIS IS THE THIRD TIME OUR CAR WILL BE GOING TO THE DEALERSHIP FOR A SERIOUS BRAKE ISSUE. THE FIRST TIME IT OCCURRED WAS IN SEPTEMBER OF 2015. THE VEHICLE WAS IN MOTION ON A RESIDENTIAL STREET WHEN THE CAR BRAKES STOPPED FUNCTIONING AS USUAL. THE DRIVER HAD TO SLAM ON THE BRAKES TO GET THE CAR TO STOP. THE CHECK BRAKE AND SERVIC…
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THIS IS THE THIRD TIME OUR CAR WILL BE GOING TO THE DEALERSHIP FOR A SERIOUS BRAKE ISSUE. THE FIRST TIME IT OCCURRED WAS IN SEPTEMBER OF 2015. THE VEHICLE WAS IN MOTION ON A RESIDENTIAL STREET WHEN THE CAR BRAKES STOPPED FUNCTIONING AS USUAL. THE DRIVER HAD TO SLAM ON THE BRAKES TO GET THE CAR TO STOP. THE CHECK BRAKE AND SERVICE LIGHTS CAME ON. THE BRAKES NO LONGER FUNCTIONED PROPERLY. THE DEALER WAS UNABLE TO REPLICATE THE ISSUE. IT HAPPENED AGAIN IN MAY OF 2016 WHEN THE CAR STARTED IN THE DRIVEWAY. AN INDEPENDENT MECHANIC WAS ABLE TO REPLICATE THE PROBLEM, WHICH WAS PRINTED OUT AND TAKEN TO THE FORD DEALERSHIP. THE DEALERSHIP WAS ABLE TO ISOLATE THE PROBLEM THIS TIME AND FIX IT. THE CAR WAS FUNCTIONAL AGAIN. TODAY, THE ISSUE HAPPENED YET AGAIN. AS THE CAR STARTED WHILE STATIONARY, THE CAR DINGED AND THE CHECK BRAKE AND SYSTEM LIGHTS CAME ON. FEARING A USER ERROR, THE DRIVER RESTARTED THE CAR AND IT SEEMED FINE. AS THE DRIVER DROVE DOWN THE RESIDENTIAL BLOCK, THE BRAKES BECAME UNRESPONSIVE AND THE SYSTEM LIGHTS CAME BACK ON. THE DRIVER HAD TO PRESS VERY HARD ON THE BRAKES TO AVOID RUNNING A STOP SIGN AND INTO ONCOMING TRAFFIC ON A NEIGHBORING STREET. THE CAR WAS TOWED TO THE DEALER.
NHTSA ODI #10920011
75,000 miles · Sep 22, 2016
Electrical SystemEngine
TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. WHILE DRIVING APPROXIMATELY 45 MPH, THE VEHICLE STALLED AND THE WRENCH WARNING INDICATOR ILLUMINATED. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD. THE VEHICLE RESTARTED NORMALLY AND WAS TAKEN TO THE DEALER THE FOLLOWING DAY, BUT WAS NOT DIAGNOSED. THE MANUFACTURER WAS N…
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TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. WHILE DRIVING APPROXIMATELY 45 MPH, THE VEHICLE STALLED AND THE WRENCH WARNING INDICATOR ILLUMINATED. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD. THE VEHICLE RESTARTED NORMALLY AND WAS TAKEN TO THE DEALER THE FOLLOWING DAY, BUT WAS NOT DIAGNOSED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 75,000.
NHTSA ODI #10908768
75,000 miles · Sep 6, 2016
Electrical SystemEngineVehicle Speed Control
DRIVING ON HIGHWAY W/ CRUISE CONTROL ENGAGED AT 65 MPH SPEED. SUDDENLY CAR LOSES COMPLETE ACCELERATION & PROPULSION ABILITY, RESULTING IN CAR TO SLOW DOWN RATHER SUDDENLY. I WAS ABLE TO PULL ONTO OFF RAMP IN MY CASE, BUT IF I WAS IN A DIFFERENT LOCATION, I WOULD HAVE DEFINITELY BEEN IN A VERY DANGEROUS SITUATION/SERIOUS ACCIDENT…
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DRIVING ON HIGHWAY W/ CRUISE CONTROL ENGAGED AT 65 MPH SPEED. SUDDENLY CAR LOSES COMPLETE ACCELERATION & PROPULSION ABILITY, RESULTING IN CAR TO SLOW DOWN RATHER SUDDENLY. I WAS ABLE TO PULL ONTO OFF RAMP IN MY CASE, BUT IF I WAS IN A DIFFERENT LOCATION, I WOULD HAVE DEFINITELY BEEN IN A VERY DANGEROUS SITUATION/SERIOUS ACCIDENT. I TURNED OFF VEHICLE AND RESTARTED THE VEHICLE A FEW MINUTES LATER. PROCEEDED TO THE HIGHWAY AGAIN, EXPERIENCED THE PROBLEM AGAIN, THIS TIME I WAS ONLY ABLE TO PULL OVER TO THE LEFT SHOULDER, WHICH WAS QUITE NARROW TO BEGIN WITH."WRENCH SYMBOL" APPEARED THE SECOND TIME AND STAYED ON WITH CHECK ENGINE LIGHT ON. CAR WAS UNSAFE TO DRIVE FURTHER. THE CHECK ENGINE TROUBLE SHOOTING CODES I HAD WERE P2111 AND P2112. CAUSE OF THIS ISSUE IS KNOWN TO FORD MOTOR BUT THEY REFUSE TO INCLUDE HYBRID CARS IN THEIR "CONSUMER SATISFACTION PROGRAM 13N03". THROTTLE BODY CONTROL MODULE SENOR, INCLUDING THE ENTIRE ASSEMBLY IS DEFECTIVE AS FORD HAS AGREED TO REPLACE THIS ON MILLIONS OF CARS ACROSS VARIOUS MODEL YEARS, INCLUDING THE FUSION 2010, BUT NOT FUSION HYBRID VERSIONS. FORD STATES THEY WILL NOT REPAIR PROBLEM THAT I EXPERIENCED RECENTLY UNDER THIS ESTABLISHED PROGRAM WHICH NHTSA WAS PROPONENT FOR. THE DEFECTIVE PART IN QUESTION IS THE THROTTLE BODY ASSEMBLY AND SENSOR WHICH IS NO DIFFERENT THAN THE PART IN THE NON-HYBRID VERSION FOR THE SAME MODEL YEAR. REAL HAZARD TO DRIVER AND I WAS LUCKY THAT I WAS NOT REAR ENDED AS A RESULT OR IN A SERIOUS CAR ACCIDENT FROM THIS KNOWN DEFECTIVE PART. FORD MOTOR MUST BE REQUIRED TO NOTIFY ALL AFFECTED OWNERS WHO WILL/HAVE EXPERIENCED THIS PROBLEM TO HAVE IT REPAIRED AT THEIR EXPENSE, AS THIS IS A SERIOUS SAFETY ISSUE THAT MUST BE TAKEN SERIOUSLY GIVEN NUMBER OF VEHICLES THAT ARE INVOLVED THAT WILL EXPERIENCE THIS. I EXPERIENCED THIS AT MILEAGE OF 75K BUT I HAVE READ THAT OTHERS HAVE HAD THIS HAPPEN AT MUCH LOWER MILEAGE.
NHTSA ODI #10904247
53,000 miles · Aug 20, 2016
Electrical SystemEngineVehicle Speed Control
MY 2010 FUSION HYBRID BEGAN A NO-START/STALLING CONDITION. IT HAS HAPPENED SIX TIMES NOW. FIRST OCCURRENCE WAS AFTER FUELING AT LOW SPEED AFTER ENTERING STREET. SECOND OCCURRENCE WAS WHILE TRAVELING ON THE HIGHWAY AT 55 MPH. THIRD OCCURRENCE WAS WHILE EXITING THE INTERSTATE. FOURTH OCCURRENCE WAS AT LOW SPEED. FIFTH OCCURRENCE …
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MY 2010 FUSION HYBRID BEGAN A NO-START/STALLING CONDITION. IT HAS HAPPENED SIX TIMES NOW. FIRST OCCURRENCE WAS AFTER FUELING AT LOW SPEED AFTER ENTERING STREET. SECOND OCCURRENCE WAS WHILE TRAVELING ON THE HIGHWAY AT 55 MPH. THIRD OCCURRENCE WAS WHILE EXITING THE INTERSTATE. FOURTH OCCURRENCE WAS AT LOW SPEED. FIFTH OCCURRENCE WAS IMMEDIATELY AFTER REFUELING WHILE STILL IN PARKING LOT. AND SIXTH OCCURENCE WAS ALSO IMMEDIATELY AFTER REFUELING JUST AFTER LEAVING GAS STATION AT LOW SPEED. FOUR OF THE SIX OCCURRENCES WAS A FAILURE FOR THE INTERNAL COMBUSTION ENGINE TO START AFTER THE ELECTRIC MOTOR HAD ALREADY BEGAN MOVING THE VEHICLE. THE OTHER TWO OCCURRENCES WAS WHILE COASTING. IN ALL INSTANCES THERE WOULD BE A RED TRIANGLE WARNING MESSAGE TO PULL OVER SAFELY, NO CODES WERE THROWN ACCORDING TO THE ENGINEERING REPORT, NO ISSUES REPORTED VIA THE VEHICLE HEALTH REPORT, THE VEHICLE WAS TRAVELING IN A MOSTLY LEVEL AND STRAIGHT LINE, AND THE VEHICLE WOULD USUALLY RESET AND RUN NORMALLY AFTER THE FIRST OR SECOND ATTEMPT AT RESTARTING ONCE THE VEHICLE WAS PULLED OVER.
NHTSA ODI #10897339
70,000 miles · Jun 12, 2016
Electrical SystemFuel/propulsion SystemVehicle Speed Control
I WAS DRIVING THE CAR ABOUT 60 MPH ON THE HIGHWAY WHEN I SAW A BIG RED TRIANGLE ON THE DISPLAY SAYING "PULL OVER AND STOP SAFELY" AND THE CAR SLOWED DOWN DRAMATICALLY. I DID THAT AND TURNED OFF THE ENGINE. I RESTARTED THE CAR. THIS OCCURRED 8 MORE TIMES BEFORE I GOT HOME (15 MILES LATER). WHEN I GOT HOME, I NOTICED THAT THE …
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I WAS DRIVING THE CAR ABOUT 60 MPH ON THE HIGHWAY WHEN I SAW A BIG RED TRIANGLE ON THE DISPLAY SAYING "PULL OVER AND STOP SAFELY" AND THE CAR SLOWED DOWN DRAMATICALLY. I DID THAT AND TURNED OFF THE ENGINE. I RESTARTED THE CAR. THIS OCCURRED 8 MORE TIMES BEFORE I GOT HOME (15 MILES LATER). WHEN I GOT HOME, I NOTICED THAT THE CAR'S FAN WAS RUNNING VERY HIGH FOR SEVERAL MINUTES. IT FINALLY STOPPED.
NHTSA ODI #10873748
81,000 miles · Jan 21, 2016
Electrical SystemSeats
WHILE DRIVING, THE DRIVER SIDE SEAT HEATER BECOMES SO HOT THAT I THOUGHT I WAS BEING BURNED. I DETECTED AN UNFAMILIAR ODOR, BUT ASSUMED IT WAS ANOTHER VEHICLES FUMES. HAD TO TURN OFF THE HEATER. ATTEMPTED TO USE ON A FEW OTHER OCCASIONS, THINKING THAT I WAS BEING OVERLY SENSITIVE. UPON MY LAST ATTEMPT, THE INDICATOR LIGHTS WOULD…
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WHILE DRIVING, THE DRIVER SIDE SEAT HEATER BECOMES SO HOT THAT I THOUGHT I WAS BEING BURNED. I DETECTED AN UNFAMILIAR ODOR, BUT ASSUMED IT WAS ANOTHER VEHICLES FUMES. HAD TO TURN OFF THE HEATER. ATTEMPTED TO USE ON A FEW OTHER OCCASIONS, THINKING THAT I WAS BEING OVERLY SENSITIVE. UPON MY LAST ATTEMPT, THE INDICATOR LIGHTS WOULD ILLUMINATE AS NORMAL, BUT WOULD SHUT OFF A FEW SECONDS LATER. THE HEATER IS NO LONGER WORKING. THE PASSENGER SIDE IS WORKING NORMALLY, BUT HAS NOT BEEN USED AS FREQUENTLY AS THE DRIVER SIDE. RESEARCHED AND THIS SEEMINGLY IS A KNOWN ISSUE. CONTACTED FORD 800-392-3673 AND THE REPRESENTATIVE STATED THAT SHE HAS HEARD OF THIS ISSUE, BUT THERE IS NOT A RECALL FOR THIS KNOWN ISSUE. MY CASE WAS DOCUMENTED, AND THE REP STATED THAT I WOULD INCUR THE COST TO HAVE THE REPAIR DONE AT THIS TIME. HMMMMMMM. I GUESS IT WILL TAKE NUMEROUS SERIOUS PERSONAL INJURIES BEING REPORTED BEFORE THIS ISSUE IS FORMALLY ADDRESSED. I MUST SAY THAT OVERALL, I DO LOVE THE FUSION !!!
NHTSA ODI #10821441
80,000 miles · Oct 29, 2015
Electrical SystemService Brakes
WAS ON HIGHWAY DRIVING 60 MPH WHEN VARIOUS BRAKE WARNING STARTED FLASHING ON DASHBOARD. WARNING SAID I NEEDED TO STOP IMMEDIATELY. I SLOWED DOWN BUT BRAKES WERE NOT RESPONSIVE. I MANAGED TO FIND AN UPHILL EXIT AND GOT THE CAR TO STOP SAFELY. I TURNED THE CAR OFF, RESTARTED IT, AND THE PROBLEM DISAPPEARED. I HAVE OWNED THIS CAR S…
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WAS ON HIGHWAY DRIVING 60 MPH WHEN VARIOUS BRAKE WARNING STARTED FLASHING ON DASHBOARD. WARNING SAID I NEEDED TO STOP IMMEDIATELY. I SLOWED DOWN BUT BRAKES WERE NOT RESPONSIVE. I MANAGED TO FIND AN UPHILL EXIT AND GOT THE CAR TO STOP SAFELY. I TURNED THE CAR OFF, RESTARTED IT, AND THE PROBLEM DISAPPEARED. I HAVE OWNED THIS CAR SINCE FEB. 2010 AND HAVE NEVER HAD THIS PROBLEM BEFORE. THE CAR HAS ABOUT 80,000 MILES ON IT.
NHTSA ODI #10787047
NHTSA investigations
6DP26004 · Anti-lock Brake System (abs) Malfunction Indicator Lamp (mil) Illuminated
Opened Apr 9, 2026 · No close date supplied
Status: open (inferred from source dates) · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
The Office of Defects Investigation (ODI) received a petition on December 22, 2025, requesting a defect investigation into the hydraulic control unit (HCU) for the Anti-lock Braking System (ABS) on the MY 2010 Ford Fusion Hybrid. The petition alleges that an illuminated ABS MIL is associated with a failure of the ABS HCU, resulting in ABS malfunction, loss of traction and electronic stability control functions, and reduced braking performance, particularly on slippery road surfaces. A defect petition has been opened to evaluate the issue and determine whether to grant or deny the petition.The petition can be reviewed at NHTSA.gov under ODI number 11647929.
DP22005 · Pedestrian Alert Sounds
Opened Jan 27, 2023 · Closed Aug 7, 2023
Status: closed (inferred from source dates) · Electrical System:propulsion System
NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.
EA17004 · Power Steering Failure
Opened Nov 20, 2017 · Closed Feb 9, 2024
Status: closed (inferred from source dates) · Steering; Steering:electric Power Assist System; Steering:rack And Pinion; Steering:rack And Pinion:rack
On September 28, 2016, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE16-011) to investigate claims of power steering assist loss on model year (MY) 2010 Ford Fusion vehicles. During the PE, ODI received 718 unique claims related to the alleged problem with 598 reports indicating the power steering assist failed while driving at various speeds with no warning. Ford Motor Company (Ford) provided 1,851 unique reports and 1,720 warranty claims related to the alleged problem. It should be noted that as the result of investigation PE14-030, Ford conducted a safety recall (15V-340) ofMY 2011-2012 Ford Fusion and other vehicles using the same electric power assist steering unit to rectify incidents of loss of power steering assist. On November 20, 2017, PE16-011 was upgraded to this Engineering Analysis (EA17-004) to further assess the scope, frequency, and consequence of this failure. This was based on an analysis of the subject vehicle complaint data that had indicated an increased likelihood of failure as the vehicles age. At the time, the rate of occurrence of this failure was comparable to previous investigations involving loss of power steering assist including the previously mentioned PE14-030. During the EA, ODI’s analysis of the alleged defect in the subject vehicles identified the following: testing showed minor steering effort changes between “assist” and “no assist”, no root cause identified, a declining failure trend, the ramp-down or reduced assist provided when a DTC is set, a lower failure rate than the recalled Fusion vehicles, and the high age of the vehicles. A safety-related defect trend has not been identified. Accordingly, this Engineering Analysis is closed. See the attached Engineering Analysis Closing Report for details. The closing of this investigation does not constitute a finding by NHTSA that a safety defect does not exist, and ODI will take further actions if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Additional source detail variants (4)
Steering:electric Power Assist System
On September 28, 2016, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE16-011) to investigate claims of power steering assist loss on model year (MY) 2010 Ford Fusion vehicles. During the PE, ODI received 718 unique claims related to the alleged problem with 598 reports indicating the power steering assist failed while driving at various speeds with no warning. Ford Motor Company (Ford) provided 1,851 unique reports and 1,720 warranty claims related to the alleged problem. It should be noted that as the result of investigation PE14-030, Ford conducted a safety recall (15V-340) ofMY 2011-2012 Ford Fusion and other vehicles using the same electric power assist steering unit to rectify incidents of loss of power steering assist. On November 20, 2017, PE16-011 was upgraded to this Engineering Analysis (EA17-004) to further assess the scope, frequency, and consequence of this failure. This was based on an analysis of the subject vehicle complaint data that had indicated an increased likelihood of failure as the vehicles age. At the time, the rate of occurrence of this failure was comparable to previous investigations involving loss of power steering assist including the previously mentioned PE14-030. During the EA, ODI’s analysis of the alleged defect in the subject vehicles identified the following: testing showed minor steering effort changes between “assist” and “no assist”, no root cause identified, a declining failure trend, the ramp-down or reduced assist provided when a DTC is set, a lower failure rate than the recalled Fusion vehicles, and the high age of the vehicles. A safety-related defect trend has not been identified. Accordingly, this Engineering Analysis is closed. See the attached Engineering Analysis Closing Report for details. The closing of this investigation does not constitute a finding by NHTSA that a safety defect does not exist, and ODI will take further actions if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Steering
On September 28, 2016, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE16-011) to investigate claims of power steering assist loss on model year (MY) 2010 Ford Fusion vehicles. During the PE, ODI received 718 unique claims related to the alleged problem with 598 reports indicating the power steering assist failed while driving at various speeds with no warning. Ford Motor Company (Ford) provided 1,851 unique reports and 1,720 warranty claims related to the alleged problem. It should be noted that as the result of investigation PE14-030, Ford conducted a safety recall (15V-340) ofMY 2011-2012 Ford Fusion and other vehicles using the same electric power assist steering unit to rectify incidents of loss of power steering assist. On November 20, 2017, PE16-011 was upgraded to this Engineering Analysis (EA17-004) to further assess the scope, frequency, and consequence of this failure. This was based on an analysis of the subject vehicle complaint data that had indicated an increased likelihood of failure as the vehicles age. At the time, the rate of occurrence of this failure was comparable to previous investigations involving loss of power steering assist including the previously mentioned PE14-030. During the EA, ODI’s analysis of the alleged defect in the subject vehicles identified the following: testing showed minor steering effort changes between “assist” and “no assist”, no root cause identified, a declining failure trend, the ramp-down or reduced assist provided when a DTC is set, a lower failure rate than the recalled Fusion vehicles, and the high age of the vehicles. A safety-related defect trend has not been identified. Accordingly, this Engineering Analysis is closed. See the attached Engineering Analysis Closing Report for details. The closing of this investigation does not constitute a finding by NHTSA that a safety defect does not exist, and ODI will take further actions if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Steering:rack And Pinion
On September 28, 2016, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE16-011) to investigate claims of power steering assist loss on model year (MY) 2010 Ford Fusion vehicles. During the PE, ODI received 718 unique claims related to the alleged problem with 598 reports indicating the power steering assist failed while driving at various speeds with no warning. Ford Motor Company (Ford) provided 1,851 unique reports and 1,720 warranty claims related to the alleged problem. It should be noted that as the result of investigation PE14-030, Ford conducted a safety recall (15V-340) ofMY 2011-2012 Ford Fusion and other vehicles using the same electric power assist steering unit to rectify incidents of loss of power steering assist. On November 20, 2017, PE16-011 was upgraded to this Engineering Analysis (EA17-004) to further assess the scope, frequency, and consequence of this failure. This was based on an analysis of the subject vehicle complaint data that had indicated an increased likelihood of failure as the vehicles age. At the time, the rate of occurrence of this failure was comparable to previous investigations involving loss of power steering assist including the previously mentioned PE14-030. During the EA, ODI’s analysis of the alleged defect in the subject vehicles identified the following: testing showed minor steering effort changes between “assist” and “no assist”, no root cause identified, a declining failure trend, the ramp-down or reduced assist provided when a DTC is set, a lower failure rate than the recalled Fusion vehicles, and the high age of the vehicles. A safety-related defect trend has not been identified. Accordingly, this Engineering Analysis is closed. See the attached Engineering Analysis Closing Report for details. The closing of this investigation does not constitute a finding by NHTSA that a safety defect does not exist, and ODI will take further actions if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Steering:rack And Pinion:rack
On September 28, 2016, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE16-011) to investigate claims of power steering assist loss on model year (MY) 2010 Ford Fusion vehicles. During the PE, ODI received 718 unique claims related to the alleged problem with 598 reports indicating the power steering assist failed while driving at various speeds with no warning. Ford Motor Company (Ford) provided 1,851 unique reports and 1,720 warranty claims related to the alleged problem. It should be noted that as the result of investigation PE14-030, Ford conducted a safety recall (15V-340) ofMY 2011-2012 Ford Fusion and other vehicles using the same electric power assist steering unit to rectify incidents of loss of power steering assist. On November 20, 2017, PE16-011 was upgraded to this Engineering Analysis (EA17-004) to further assess the scope, frequency, and consequence of this failure. This was based on an analysis of the subject vehicle complaint data that had indicated an increased likelihood of failure as the vehicles age. At the time, the rate of occurrence of this failure was comparable to previous investigations involving loss of power steering assist including the previously mentioned PE14-030. During the EA, ODI’s analysis of the alleged defect in the subject vehicles identified the following: testing showed minor steering effort changes between “assist” and “no assist”, no root cause identified, a declining failure trend, the ramp-down or reduced assist provided when a DTC is set, a lower failure rate than the recalled Fusion vehicles, and the high age of the vehicles. A safety-related defect trend has not been identified. Accordingly, this Engineering Analysis is closed. See the attached Engineering Analysis Closing Report for details. The closing of this investigation does not constitute a finding by NHTSA that a safety defect does not exist, and ODI will take further actions if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
PE16011 · Power Steering Failure
Opened Sep 28, 2016 · Closed Dec 25, 2017
Status: closed (inferred from source dates) · Steering; Steering:electric Power Assist System
On September 28th, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation PE16-011 to investigate claims of power steering assist loss on model year 2010 Ford Fusion vehicles.ODI has received 718 unique claims related to the alleged problem with 598 reports indicating the power steering assist failed while driving at speed with no warning.During the PE16-011 investigation, Ford Motor Company (Ford) provided 1851 unique reports and 1720 warranty claims related to the alleged problem.As the result of investigation PE14-030, Ford previously conducted a recall (15V-340) of the 2011-2012 Ford Fusion and other vehicles using the same electric power assist steering unit to rectify incidents of loss of power steering assist.An analysis of the subject vehicle complaint data indicates an increased likelihood of failure as the vehicles age.The rate of occurrence of this failure is comparable to previous investigations involving loss of power steering assist including the previously mentioned PE14-030.Therefore, the Preliminary Evaluation (PE16-011) has been upgraded to an Engineering Analysis to further assess the scope, frequency and consequence of this failure. ODI reports cited above can be reviewed at https://www.nhtsa.gov/recalls#vehicle under the identification (NHTSA ID) numbers found in the attached list.
Additional source detail variants (2)
Steering:electric Power Assist System
On September 28th, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation PE16-011 to investigate claims of power steering assist loss on model year 2010 Ford Fusion vehicles.ODI has received 718 unique claims related to the alleged problem with 598 reports indicating the power steering assist failed while driving at speed with no warning.During the PE16-011 investigation, Ford Motor Company (Ford) provided 1851 unique reports and 1720 warranty claims related to the alleged problem.As the result of investigation PE14-030, Ford previously conducted a recall (15V-340) of the 2011-2012 Ford Fusion and other vehicles using the same electric power assist steering unit to rectify incidents of loss of power steering assist.An analysis of the subject vehicle complaint data indicates an increased likelihood of failure as the vehicles age.The rate of occurrence of this failure is comparable to previous investigations involving loss of power steering assist including the previously mentioned PE14-030.Therefore, the Preliminary Evaluation (PE16-011) has been upgraded to an Engineering Analysis to further assess the scope, frequency and consequence of this failure. ODI reports cited above can be reviewed at https://www.nhtsa.gov/recalls#vehicle under the identification (NHTSA ID) numbers found in the attached list.
Steering
On September 28th, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation PE16-011 to investigate claims of power steering assist loss on model year 2010 Ford Fusion vehicles.ODI has received 718 unique claims related to the alleged problem with 598 reports indicating the power steering assist failed while driving at speed with no warning.During the PE16-011 investigation, Ford Motor Company (Ford) provided 1851 unique reports and 1720 warranty claims related to the alleged problem.As the result of investigation PE14-030, Ford previously conducted a recall (15V-340) of the 2011-2012 Ford Fusion and other vehicles using the same electric power assist steering unit to rectify incidents of loss of power steering assist.An analysis of the subject vehicle complaint data indicates an increased likelihood of failure as the vehicles age.The rate of occurrence of this failure is comparable to previous investigations involving loss of power steering assist including the previously mentioned PE14-030.Therefore, the Preliminary Evaluation (PE16-011) has been upgraded to an Engineering Analysis to further assess the scope, frequency and consequence of this failure. ODI reports cited above can be reviewed at https://www.nhtsa.gov/recalls#vehicle under the identification (NHTSA ID) numbers found in the attached list.
PE14030 · Electric Power Steering Failure
Opened Oct 2, 2014 · Closed Sep 10, 2015
Status: closed (inferred from source dates) · Steering:electric Power Assist System
The Office of Defects Investigation (ODI) opened a preliminary evaluation to investigate complaints of the loss of power steering while driving. The subject vehicles are equipped with a rack mounted Electric Power Assisted Steering (EPAS) unit.Some of the complaints alleged that the steering assist failed and resulted in increased steering efforts that contributed to a loss of control and in some cases a crash.The EPAS system was manufactured by TRW Automotive for Ford and was designated as Generation I.These units were first produced and put into vehicle production in July 2008 beginning with the model year (MY) 2010 Ford Fusion and Mercury Milan.The system is comprised of a mechanical steering rack-and-pinion gear with torque sensor, electric assist motor, motor position sensor and a power steering control module (PSCM). The PSCM is self-monitoring and designed to detect faults within the system and can store diagnostic trouble codes (DTCs) if a problem is detected.There are 29 potential DTCs the system can detect.Many of these allow the system to go into reduced-assist steering mode by using the default vehicle speed signal should the live speed signal be lost, if voltage to EPAS system falls below 10.7 or goes above 17 volts, the temperature at the PSCM goes above 105C (221F), or if high friction is detected.Some DTCs will cause the system to go into manual steering mode (no assist). On July 1, 2015, Ford filed a Defect Information Report (DIR) identifying a safety related defect in TRW GEN I EPAS systems installed in some of the subject vehicles (NHTSA Recall 15V-340, Ford No. 15S18).The DIR indicated that intermittent electrical connections caused by quality issues associated with conformal coat contamination and ribbon cable pin misalignment within the steering gear motor may lead to a loss of the motor position sensor signal, resulting in a sudden loss of power assist while driving.The recall covers approximately 393,623 vehicles built from September 2010 through February 2012:2011-12 Fusion built SEP 2010 - FEB 2012; 2011-12 Lincoln MKZ built SEP 2010 - FEB 2012; 2011 Milan built SEP 2010 - DEC 2010; 2011-13 Taurus built SEP 2010 - FEB 2012; 2011-13 Flex with 3.5L GTDI engine built SEP 2010 - FEB 2012; and 2011-13 MKS, MKT with 3.5L GTDI engine built SEP 2010 - FEB 2012.The repair consists of updating the PSCM software to prevent a loss of steering assist while driving. The revised software will provide audible and visual warnings to the driver. If one or more of the following DTCs are stored, C1B00-62, C200B-2F, C200B-61, C200B-62, C200C-2F, C200D-49, U0300-00, U2011-49, U2011-61, U3000-46, U3000-49, U3000-61, U3000-72, U3000-96, P07AE-09, the dealer will replace the EPAS system at no charge to the owner.ODI's analysis of failure data for this PE identified a total of 2,584 complaints to ODI and Ford and 9,967 Ford warranty claims related to the alleged defect.The recalled vehicles account for 1,634 of the complaints and 7,311 of the warranty claims.ODI's analysis identified 40 complaints alleging crashes that may be related to loss of steering assist while driving, 20 of which involved vehicles included in Ford's recall.The information available for the alleged crashes were not sufficient to assess specific causes of the incidents or to verify EPAS malfunctions in each case.Most of the crashes were low-speed impacts with curbs or roadside objects resulting in wheel or minor body damage.None of the injury claims indicated medical attention was required.In addition, statistical modeling of the failure data by NHTSA's National Center for Statistics and Analysis projected 10-year failur
EA12009 · Floor Mat Interference With Accelerator
Opened Dec 12, 2012 · Closed Jun 12, 2014
Status: closed (inferred from source dates) · Vehicle Speed Control; Vehicle Speed Control:accelerator Pedal
On May 27, 2014, Ford Motor Company submitted recall 14E-028 (Ford recall #14S07) to correct a safety-related problem with certain driver's side Ford optional all-weather floor mats sold for use in model year 2006 through 2011 model year Ford Fusion, Mercury Milan, Lincoln Zephyr, and Lincoln MKZ vehicles built at Hermosillo Assembly Plant (HAP) from November 9, 2007, to October 31 ,2010.NHTSA testing determined that the original accessory all-weather mat with a single retention clip (Figure 1), may interfere with accelerator pedal return to idle with the mat retained by the clip and rotated clockwise.Both the single- and double-clip (Figure 2) all-weather floor mats may interfere with the accelerator pedal return to idle when the mats are not secured by the retention clip(s).Testing showed that this can occur if the mats are moved forward from the clipped position approximately two inches into a position in which the rear edge of the mats will abut the retention clip(s) when installed singly and align with the clip(s) when stacked on another floor mat.The pedal interference incidents reviewed by the Office of Defects Investigation (ODI) include 1 crash and 9 incidents with allegations of brake friction materials smoking and/or requiring repair for heat related damage.The crash incident occurred after the parking brake was applied at speed, resulting in loss-of-control vehicle yaw event caused by lock-up of the rear tires.The spin-out resulted in a side impact collision with an oncoming vehicle in an opposing lane of traffic. For the 29 incidents with sufficient information available to make an assessment; 23 (79%) were controlled by the driver either shifting to neutral, turning the engine off, or both; 4 (14%) were ended by the driver either kicking the pedal free (2) or pulling the mat away from the pedal (2); and 2 (7%) were ended by the pedal freeing itself from the mat with no apparent driver action.None of the drivers who reacted to the incident by shifting to neutral or turning the engine off reported any difficulties with either action.The subject mats were sold by Ford and Lincoln dealers directly to customers as an optional accessory equipment item or, beginning in November 2007, the mats were also available as a factory installed accessory if ordered with a new vehicle.Ford estimates that approximately 82,579 affected driver's side all weather floor mats were sold worldwide; either over the counter through Ford dealerships or as original equipment.Owners that purchased the subject all-weather floor mats as a factory installed accessory with their new vehicle will be notified to return their all weather floor mats to their Ford or Lincoln Dealership in exchange for replacement mats.Owners of all other potentially affected vehicles will be notified that, if they have an affected Ford driver's side all weather floor mat, they should return their mats to the dealership in exchange for replacement mats.The VOQs associated with the closing of this investigation are: 10327597, 10332233, 10334211, 10335336, 10339330, 10348772 (and duplicate 10342572), 10372674, 10379562, 10415911, 10426255, 10434107, 10521053, 10554966.This investigation is hereby closed.
Additional source detail variants (2)
Vehicle Speed Control:accelerator Pedal
On May 27, 2014, Ford Motor Company submitted recall 14E-028 (Ford recall #14S07) to correct a safety-related problem with certain driver's side Ford optional all-weather floor mats sold for use in model year 2006 through 2011 model year Ford Fusion, Mercury Milan, Lincoln Zephyr, and Lincoln MKZ vehicles built at Hermosillo Assembly Plant (HAP) from November 9, 2007, to October 31 ,2010.NHTSA testing determined that the original accessory all-weather mat with a single retention clip (Figure 1), may interfere with accelerator pedal return to idle with the mat retained by the clip and rotated clockwise.Both the single- and double-clip (Figure 2) all-weather floor mats may interfere with the accelerator pedal return to idle when the mats are not secured by the retention clip(s).Testing showed that this can occur if the mats are moved forward from the clipped position approximately two inches into a position in which the rear edge of the mats will abut the retention clip(s) when installed singly and align with the clip(s) when stacked on another floor mat.The pedal interference incidents reviewed by the Office of Defects Investigation (ODI) include 1 crash and 9 incidents with allegations of brake friction materials smoking and/or requiring repair for heat related damage.The crash incident occurred after the parking brake was applied at speed, resulting in loss-of-control vehicle yaw event caused by lock-up of the rear tires.The spin-out resulted in a side impact collision with an oncoming vehicle in an opposing lane of traffic. For the 29 incidents with sufficient information available to make an assessment; 23 (79%) were controlled by the driver either shifting to neutral, turning the engine off, or both; 4 (14%) were ended by the driver either kicking the pedal free (2) or pulling the mat away from the pedal (2); and 2 (7%) were ended by the pedal freeing itself from the mat with no apparent driver action.None of the drivers who reacted to the incident by shifting to neutral or turning the engine off reported any difficulties with either action.The subject mats were sold by Ford and Lincoln dealers directly to customers as an optional accessory equipment item or, beginning in November 2007, the mats were also available as a factory installed accessory if ordered with a new vehicle.Ford estimates that approximately 82,579 affected driver's side all weather floor mats were sold worldwide; either over the counter through Ford dealerships or as original equipment.Owners that purchased the subject all-weather floor mats as a factory installed accessory with their new vehicle will be notified to return their all weather floor mats to their Ford or Lincoln Dealership in exchange for replacement mats.Owners of all other potentially affected vehicles will be notified that, if they have an affected Ford driver's side all weather floor mat, they should return their mats to the dealership in exchange for replacement mats.The VOQs associated with the closing of this investigation are: 10327597, 10332233, 10334211, 10335336, 10339330, 10348772 (and duplicate 10342572), 10372674, 10379562, 10415911, 10426255, 10434107, 10521053, 10554966.This investigation is hereby closed.
Vehicle Speed Control
On May 27, 2014, Ford Motor Company submitted recall 14E-028 (Ford recall #14S07) to correct a safety-related problem with certain driver's side Ford optional all-weather floor mats sold for use in model year 2006 through 2011 model year Ford Fusion, Mercury Milan, Lincoln Zephyr, and Lincoln MKZ vehicles built at Hermosillo Assembly Plant (HAP) from November 9, 2007, to October 31 ,2010.NHTSA testing determined that the original accessory all-weather mat with a single retention clip (Figure 1), may interfere with accelerator pedal return to idle with the mat retained by the clip and rotated clockwise.Both the single- and double-clip (Figure 2) all-weather floor mats may interfere with the accelerator pedal return to idle when the mats are not secured by the retention clip(s).Testing showed that this can occur if the mats are moved forward from the clipped position approximately two inches into a position in which the rear edge of the mats will abut the retention clip(s) when installed singly and align with the clip(s) when stacked on another floor mat.The pedal interference incidents reviewed by the Office of Defects Investigation (ODI) include 1 crash and 9 incidents with allegations of brake friction materials smoking and/or requiring repair for heat related damage.The crash incident occurred after the parking brake was applied at speed, resulting in loss-of-control vehicle yaw event caused by lock-up of the rear tires.The spin-out resulted in a side impact collision with an oncoming vehicle in an opposing lane of traffic. For the 29 incidents with sufficient information available to make an assessment; 23 (79%) were controlled by the driver either shifting to neutral, turning the engine off, or both; 4 (14%) were ended by the driver either kicking the pedal free (2) or pulling the mat away from the pedal (2); and 2 (7%) were ended by the pedal freeing itself from the mat with no apparent driver action.None of the drivers who reacted to the incident by shifting to neutral or turning the engine off reported any difficulties with either action.The subject mats were sold by Ford and Lincoln dealers directly to customers as an optional accessory equipment item or, beginning in November 2007, the mats were also available as a factory installed accessory if ordered with a new vehicle.Ford estimates that approximately 82,579 affected driver's side all weather floor mats were sold worldwide; either over the counter through Ford dealerships or as original equipment.Owners that purchased the subject all-weather floor mats as a factory installed accessory with their new vehicle will be notified to return their all weather floor mats to their Ford or Lincoln Dealership in exchange for replacement mats.Owners of all other potentially affected vehicles will be notified that, if they have an affected Ford driver's side all weather floor mat, they should return their mats to the dealership in exchange for replacement mats.The VOQs associated with the closing of this investigation are: 10327597, 10332233, 10334211, 10335336, 10339330, 10348772 (and duplicate 10342572), 10372674, 10379562, 10415911, 10426255, 10434107, 10521053, 10554966.This investigation is hereby closed.
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