IllustrationSTEERING WHEEL RECALL. CONSTANT STOP SAFELY NOW PROMPT CAUSING THE CAR TO BE UNSAFE ON THE HIGHWAY. IF I DRIVE FOR AN HOUR OR MORE THIS BEGINS HAPPENING AT SPEEDS OVER 60 MILES PER HOUR
2010 Ford Fusion Hybrid
Owner reports · Recalls · Investigations
More warning signs than most Fusion Hybrid years
Owner complaints for the 2010 Ford Fusion Hybrid are substantially higher than the model-year median of 65.
About this comparison →How this year compares
Owner complaints by model year
Compare all Fusion Hybrid years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
100–25K
3625–50K
8950–75K
8675–100K
110100–150K
44150K+
375 reports with mileage · 133 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Steering. Review the 138 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 135 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes. Review the 79 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
9 crash reports0 fire reports2 injury reports
Engine complaints
46 reportsSTARTING JULY 2017 I NOTICED THAT MY THE GASOLINE ENGINE OF FUSION HYBRID HAD DEVELOPED A NOTICEABLY "ROUGH" IDLE WHEN IT CAME ON. IT ALSO RAN "ROUGH" AND HAD AN UNEVEN THROTTLE RESPONSE. A YELLOW WRENCH WOULD ALSO APPEAR OCCASIONALLY ON THE DISPLAY PANEL. THE OWNERS MANUAL INDICATED A "THROTTLE CONTROL/POWERTRAIN MALFUNCTION"AN…
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STARTING JULY 2017 I NOTICED THAT MY THE GASOLINE ENGINE OF FUSION HYBRID HAD DEVELOPED A NOTICEABLY "ROUGH" IDLE WHEN IT CAME ON. IT ALSO RAN "ROUGH" AND HAD AN UNEVEN THROTTLE RESPONSE. A YELLOW WRENCH WOULD ALSO APPEAR OCCASIONALLY ON THE DISPLAY PANEL. THE OWNERS MANUAL INDICATED A "THROTTLE CONTROL/POWERTRAIN MALFUNCTION"AND RECOMMENDED CONTACTING THE AUTHORIZED DEALER. BILL COLLINS FORD IN LOUISVILLE ,KY CHECKED AND RAN DIAGNOSTICS BUT COULD NOT FIND ANYTHING WRONG. ON SEPTEMBER 25, WHILE DRIVING TO WORK IN THE MORNING THE CAR EXPERIENCED A SUDDEN DRASTIC DROP IN SPEED GOING FROM ABOUT 65MPH TO ABOUT 30MPH. THE CAR BECOME UNRESPONSIVE TO THE THROTTLE. THE GASOLINE ENGINE HAD COMPLETELY SHUT DOWN AND THE CAR WAS LIMPING ALONG POWERED BY THE ELECTRIC ENGINE. BOTH THE WRENCH AND THE CHECK ENGINE INDICATORS LIT UP ON THE DISPLAY AND STAYED ON. LUCKILY I MADE IT OFF THE EXPRESSWAY AND GOT TO WORK. THIS WAS VERY SCARY AND I WAS LUCKY TO NOT BE REAR ENDED OR CRASHING THE CAR. WHEN I ATTEMPTED TO RESTART AFTER ABOUT THREE HOURS THE THE GASOLINE ENGINE CAME BACK ON BUT WITH A VERY "ROUGH" IDLE. I WAS ABLE TO DRIVE THE CAR TO THE DEALERSHIP. THIS TIME THEY DIAGNOSED A PROBLEM WITH THE ELECTRONIC THROTTLE BODY AND FOR ABOUT $600 REPLACED THE ETB, CLEANED THE "MASS AIR FLOW SENSOR" AND "REPROGRAMMED THE COMPUTER". HOWEVER, THE THE CAR CONTINUES TO IDLE "ROUGH" AND HAS POOR THROTTLE RESPONSE, WHICH WERE ISSUES THE CAR HAD LEADING INTO THE LOSS OF POWER ON THE EXPRESSWAY. THE DEALERSHIP DOES NOT KNOW HOW TO FIX THIS PROBLEM AND CLAIMS TO BE IN TOUCH THE FORD FACTORY ENGINEERS TO FIND A SOLUTION. THERE IS NO RESPONSE SO FAR. SEARCHING ON THE INTERNET, I UNDERSTAND THIS IS A KNOWN ISSUE WITH FORD FUSIONS PARTICULARLY THE 2010 MODEL YEAR. NHTSA MANDATED A RECALL PROBLEM FOR 2010 FUSIONS GASOLINE ENGINES BUT NOT HYBRID MODELS!
THE CAR WAS MOVING AT 40 MPH IN A STRAIGHT LINE ON A FLAT ROAD AND THE RTT LIGHT AND TWO WRENCHES CAME ON AND SPEED DROPPED TO 30 MPH AND NO MATTER WHAT, SPEED WOULD NOT INCREASE. STOPPING AND TURNING THE KEY ON AND OFF SOLVED PROBLEM FOR A SHORT TIME THEN HAPPEN AGAIN. FORD HAS RECALL FOR THROTTLE BODY EXCEPT FOR HYBRIDS WHY?…
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THE CAR WAS MOVING AT 40 MPH IN A STRAIGHT LINE ON A FLAT ROAD AND THE RTT LIGHT AND TWO WRENCHES CAME ON AND SPEED DROPPED TO 30 MPH AND NO MATTER WHAT, SPEED WOULD NOT INCREASE. STOPPING AND TURNING THE KEY ON AND OFF SOLVED PROBLEM FOR A SHORT TIME THEN HAPPEN AGAIN. FORD HAS RECALL FOR THROTTLE BODY EXCEPT FOR HYBRIDS WHY? CAR HAS 83,000 MILES
MY FORD FUSION HYBRID 2010 STALLED WITHOUT ANY WARNING IN THE 5TH LANE OF I-85 IN ATLANTA. MY WIFE, THE RESPONDING POLICE OFFICER, AND MYSELF WERE IN GRAVE DANGER BECAUSE OF THIS. WE WERE BLESSED AND FORTUNATE THAT AN OFFICER HAPPENED TO BE VERY CLOSE WHEN OUR CAR SUDDENLY DIED IN THE MIDDLE OF THE INTERSTATE. THE INTERSTAT…
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MY FORD FUSION HYBRID 2010 STALLED WITHOUT ANY WARNING IN THE 5TH LANE OF I-85 IN ATLANTA. MY WIFE, THE RESPONDING POLICE OFFICER, AND MYSELF WERE IN GRAVE DANGER BECAUSE OF THIS. WE WERE BLESSED AND FORTUNATE THAT AN OFFICER HAPPENED TO BE VERY CLOSE WHEN OUR CAR SUDDENLY DIED IN THE MIDDLE OF THE INTERSTATE. THE INTERSTATE TRAFFIC WAS HEAVY - BUT SLOW MOVING DUE TO CONSTRUCTION. THE OFFICER RESPONDED - LITERALLY - WITHIN SECONDS SINCE HE SAW WHAT WAS HAPPENING. HE PLACED HIS CAR BEHIND OURS WITH HIS LIGHTS FLASHING. THE THE OFFICER AND I HAD TO PUSH MY VEHICLE OFF TO THE SIDE. WE WERE ALL IN GRAVE DANGER! AS THE OFFICER WAS CALLING FOR HELP AND A WRECKER, MY CAR SUDDENLY BEGAN WORKING AFTER SEVERAL MINUTES. THIS WAS AN EXTREMELY DANGEROUS SITUATION. I THEN RESEARCHED THIS PROBLEM ON THE INTERNET AFTER I RETURNED HOME ONLY TO DISCOVER THAT MANY OTHER FORD FUSION OWNERS HAVE EXPERIENCED THE SAME PROBLEM OF RANDOM STALLING. THIS IS TOTALLY UNACCEPTABLE! WHAT IS FORD WAITING FOR TO RECALL THIS VEHICLE?? I HAVE NO CONFIDENCE DRIVING THIS CAR NOW. IT'S ONLY A MATTER OF TIME UNTIL A TRAGEDY OCCURS BECAUSE OF THIS. (IF IT HASN'T HAPPENED ALREADY)
HAD TO REPLACE FRONT WHEEL BEARINGS 1000+ AFTER ONLY 80,000 MILES. ADDITIONALLY, HAD TO REPLACE A SPEAKER FOR THE BACK UP SYSTEM. WHAT KIND OF IDIOTS ARE THEY. SAFETY ISSUE: I ALSO TO HAVE THROTTLE BODY WORK DONE 2 YEARS AGO AND THE LAST 10 DAYS, 31 JULY TO 9 AUG, HAVE HAD 6 EPISODES OF THE WRENCH LIGHT COMING ON WITH TWO OF…
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HAD TO REPLACE FRONT WHEEL BEARINGS 1000+ AFTER ONLY 80,000 MILES. ADDITIONALLY, HAD TO REPLACE A SPEAKER FOR THE BACK UP SYSTEM. WHAT KIND OF IDIOTS ARE THEY. SAFETY ISSUE: I ALSO TO HAVE THROTTLE BODY WORK DONE 2 YEARS AGO AND THE LAST 10 DAYS, 31 JULY TO 9 AUG, HAVE HAD 6 EPISODES OF THE WRENCH LIGHT COMING ON WITH TWO OF THEM RESULTING IN SUDDEN DECELERATION ON THE FREEWAY.
WHILE DRIVING AT 65 MPH YELLOW WRENCH LIGHT APPEARED AND VEHICLE LOST ALL POWER. THIS WAS ON A BUSY HIGHWAY. PULLED OVER AND RESTARTED CAR. VEHICLE OPERATED SMOOTHLY. TWO DAYS LATER SAME ISSUE, NOW WITH YELLOW WRENCH AND CHECK ENGINE LIGHT. VEHICLE WILL NOT ACCELERATE ABOVE 30 MPH. I TOOK MY VEHICLE TO LOCAL AUTO PARTS STORE AND…
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WHILE DRIVING AT 65 MPH YELLOW WRENCH LIGHT APPEARED AND VEHICLE LOST ALL POWER. THIS WAS ON A BUSY HIGHWAY. PULLED OVER AND RESTARTED CAR. VEHICLE OPERATED SMOOTHLY. TWO DAYS LATER SAME ISSUE, NOW WITH YELLOW WRENCH AND CHECK ENGINE LIGHT. VEHICLE WILL NOT ACCELERATE ABOVE 30 MPH. I TOOK MY VEHICLE TO LOCAL AUTO PARTS STORE AND PULLED CODES MYSELF (115) DOLLARS CHEAPER THEN THE DEALERSHIP WOULD HAVE DONE IT. THROTTLE BODY CONTROL FAILURE. THIS IS THE SAME ENGINE THAT HAS EXTENDED WARRANTY FOR ALOT OF VIN NUMBERS BUT MY CAR HAS THIS ISSUE AMD ISNT COVERED.
WHILE DRIVING DOWN THE EXPRESSWAY (475) THERE WAS A LOSS ON POWER AND THE CAR WENT INTO WHAT IS CALL THE "LIMP HOME MODE" WHILE TRAFFIC SURGED AROUND WE MAKING IT VERY DANGEROUS TO TRAVEL AT THIS SLOW SPEED. "WENCH" CODES WERE DISPLAYED ON THE SCREEN. AFTER FINDING THE NEAREST EXIT I RESTARTED THE CAR WHICH PUT IT BACK INTO NORM…
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WHILE DRIVING DOWN THE EXPRESSWAY (475) THERE WAS A LOSS ON POWER AND THE CAR WENT INTO WHAT IS CALL THE "LIMP HOME MODE" WHILE TRAFFIC SURGED AROUND WE MAKING IT VERY DANGEROUS TO TRAVEL AT THIS SLOW SPEED. "WENCH" CODES WERE DISPLAYED ON THE SCREEN. AFTER FINDING THE NEAREST EXIT I RESTARTED THE CAR WHICH PUT IT BACK INTO NORMAL DRIVING MODE AND DROVE HOME. DURING THE DRIVE HOME THE "CHECK ENGINE " CAME ON BUT CONTINUED NORMALLY. SAME THING HAPPENED THE NEXT DAY WITH LOSS OF POWER AND WRENCH CODES.
ENGINE LIGHT WARNING FOR THE CANISTER PURGE VALVE RECEIVED. FORD NEWS SITE (11/23/15) STATED A SAFETY RECALL TO BE ISSUE FOR 2010-11 FUSIONS FOR THIS ISSUE AND I BELIEVE WE SHOULD HAVE RECEIVED ONE AS OUR CAR FALLS IN THE DATES STATED. OUR VIN IS NOT LISTING THIS AS A RECALL AND WE ARE HAVING TO PAY OUT OF POCKET FOR A NOTED REC…
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ENGINE LIGHT WARNING FOR THE CANISTER PURGE VALVE RECEIVED. FORD NEWS SITE (11/23/15) STATED A SAFETY RECALL TO BE ISSUE FOR 2010-11 FUSIONS FOR THIS ISSUE AND I BELIEVE WE SHOULD HAVE RECEIVED ONE AS OUR CAR FALLS IN THE DATES STATED. OUR VIN IS NOT LISTING THIS AS A RECALL AND WE ARE HAVING TO PAY OUT OF POCKET FOR A NOTED RECALL REPAIR. CAR WAS STATIONARY WHEN THE ENGINE LIGHT CAME ON.
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.
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.
Official recalls
0No recalls in this snapshot.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
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.