NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
46 reportsClear category filter70,000 miles · Jul 15, 2015
Engine
I'VE EXPERIENCED THE "LIMP HOME MODE" PROBLEM DESCRIBED IN FORD'S CONSUMER SATISFACTION PROGRAM 13N03. THIS HAS OCCURRED 4 TIMES NOW AND IS A VERY SCARY AND VERY UNSAFE PROBLEM. I TOOK MY CAR TO THE LOCAL FORD DEALER (DAVID MCDAVID) IN FORT WORTH. THEY DETERMINED THE PROBLEM IS A DEFECT IN THE THROTTLE BODY HOWEVER THEY WILL…
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I'VE EXPERIENCED THE "LIMP HOME MODE" PROBLEM DESCRIBED IN FORD'S CONSUMER SATISFACTION PROGRAM 13N03. THIS HAS OCCURRED 4 TIMES NOW AND IS A VERY SCARY AND VERY UNSAFE PROBLEM. I TOOK MY CAR TO THE LOCAL FORD DEALER (DAVID MCDAVID) IN FORT WORTH. THEY DETERMINED THE PROBLEM IS A DEFECT IN THE THROTTLE BODY HOWEVER THEY WILL NOT FIX IT UNDER THE TERMS OF 13N03 AS FORD BELIEVES IT DOES NOT APPLY TO THE HYBRID. I CAN ASSURE YOU IT APPLIES. PERHAPS DUE TO THE LOW NUMBER OF FUSION HYRID'S ON THE ROAD THIS HAS NOT YET RECEIVED MUCH ATTENTION. PLEASE ADD THE FUSION HYBRID TO THE LIST OF MODELS EXPERIENCING THE LIMP HOME MODE ISSUE AND URGE FORD TO CORRECT IT AS PART OF 13N03 UPDATED 11/27/2017*CN
NHTSA ODI #10734417
76,000 miles · Jul 5, 2015
Engine
DURING NORMAL DRIVING, WRENCH LIGHT CAME ONE. SOON AFTER THE LIGHT CAME ON THE VEHICLE LOST ENGINE POWER. THE CAR WAS TAKEN TO A FORD DEALER AND IT TURNED OUT TO BE A DEFECTIVE ELECTRONIC THROTTLE BODY. AFTER A BIT OF RESEARCH I FOUND OUT THAT FORD HAS A CUSTOMER SATISFACTION PROGRAM ON THIS FOR CERTAIN VEHICLES BUT I WAS VER…
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DURING NORMAL DRIVING, WRENCH LIGHT CAME ONE. SOON AFTER THE LIGHT CAME ON THE VEHICLE LOST ENGINE POWER. THE CAR WAS TAKEN TO A FORD DEALER AND IT TURNED OUT TO BE A DEFECTIVE ELECTRONIC THROTTLE BODY. AFTER A BIT OF RESEARCH I FOUND OUT THAT FORD HAS A CUSTOMER SATISFACTION PROGRAM ON THIS FOR CERTAIN VEHICLES BUT I WAS VERY UPSET WHEN I FOUND OUT MY VEHICLE WAS NOT INCLUDED ON THIS PROGRAM.
NHTSA ODI #10732042
39,000 miles · May 11, 2015
EngineFuel/propulsion SystemVehicle Speed Control
FIRST TIME, CHECK ENGINE LIGHT CAME ON WHEN DRIVING ON HIGHWAY BUT NO APPARENT IMPACT TO CAR'S FUNCTIONING. TOOK IT TO THE DEALER. THEY SAID THAT THE SURGE VALVE NEEDED TO BE REPLACED AT A COST OF $500 "TO START WITH", BUT THEY DIDN'T SEEM VERY SURE ABOUT IT SO I CHOSE NOT TO PROCEED. THE CHECK ENGINE LIGHT HAD GONE BACK OFF …
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FIRST TIME, CHECK ENGINE LIGHT CAME ON WHEN DRIVING ON HIGHWAY BUT NO APPARENT IMPACT TO CAR'S FUNCTIONING. TOOK IT TO THE DEALER. THEY SAID THAT THE SURGE VALVE NEEDED TO BE REPLACED AT A COST OF $500 "TO START WITH", BUT THEY DIDN'T SEEM VERY SURE ABOUT IT SO I CHOSE NOT TO PROCEED. THE CHECK ENGINE LIGHT HAD GONE BACK OFF AND THE CAR WAS DRIVING FINE. ABOUT TWO WEEKS LATER ON A SATURDAY I WAS DRIVING ON THE HIGHWAY AGAIN, AT ABOUT 65 MPH, WHEN THE CAR SEEMED TO LOSE ACCELERATION. STANDING ON GAS PEDAL PRODUCED NO RESULT. EXITED AND WAS ABLE TO DRIVE ON BATTERY POWER TO PULL OVER. AFTER WAITING FOR ABOUT 30 MINUTES, TRIED AGAIN. CHECK ENGINE LIGHT WAS BACK OFF AND CAR DROVE NORMALLY BACK HOME. TOOK TO MY REGULAR MECHANIC FIRST THING THAT MONDAY. THEY FOUND OIL IN THE INTAKE MANIFOLD AND QUESTIONED WHETHER I HAD TAKEN THE CAR ANYWHERE UNUSUAL FOR SERVICING, WHICH I HAD NOT, UNLESS YOU COUNT THE DEALER. DID REPAIRS AT A COST OF $2000. ONE WEEK LATER, EXACT SAME THING. CAR IS BACK IN SHOP, AWAITING RESULTS.
NHTSA ODI #10715780
53,000 miles · Mar 19, 2015
EnginePower Train
GAS ENGINE SPUTTERING AND ESSENTIALLY NO POWER WHEN STEPPED ON ACCELERATOR. TURNED CAR OFF/ON, STILL SPUTTERING AND THE CHECK ENGINE LIGHT CAME ON. ABLE TO LIMP BACK TO GARAGE. TWO HOURS LATER ENGINE RUNNING BUT CHECK ENGINE LIGHT STILL ON. INITIALLY AT MECHANICS RUNNING OK, BUT THEN SPUTTERED FOR THEM AS WELL. SYSTEM CHECK…
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GAS ENGINE SPUTTERING AND ESSENTIALLY NO POWER WHEN STEPPED ON ACCELERATOR. TURNED CAR OFF/ON, STILL SPUTTERING AND THE CHECK ENGINE LIGHT CAME ON. ABLE TO LIMP BACK TO GARAGE. TWO HOURS LATER ENGINE RUNNING BUT CHECK ENGINE LIGHT STILL ON. INITIALLY AT MECHANICS RUNNING OK, BUT THEN SPUTTERED FOR THEM AS WELL. SYSTEM CHECK SUGGESTED ISSUE WITH FUEL INJECTORS, THOUGH GIVEN OTHER REPORTS OF THROTTLE BODY PROBLEMS WILL NEED TO FURTHER INVESTIGATE. *TR
NHTSA ODI #10695311
33,000 miles · Oct 28, 2014
EngineFuel/propulsion SystemVehicle Speed Control
MY HYBRID EXPERIENCED LOSS OF POWER ON 2 OCCASIONS.1ST WAS AT APPROXIMATELY 33,000 MI ON SEP 6, 2014. DRIVING 35MPH ON A PARKWAY WRENCHES APPEARED ON THE DASHBOARD DISPLAY & THEN SUDDEN & IMMEDIATE LOSS OF POWER FOLLOWED.NO RESPONSE TO FULL ACCELERATOR PUSH. MOTOR POWER SHUT DOWN & ONLY ELECTRIC POWER ALLOWED US TO LIMP OFF THE …
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MY HYBRID EXPERIENCED LOSS OF POWER ON 2 OCCASIONS.1ST WAS AT APPROXIMATELY 33,000 MI ON SEP 6, 2014. DRIVING 35MPH ON A PARKWAY WRENCHES APPEARED ON THE DASHBOARD DISPLAY & THEN SUDDEN & IMMEDIATE LOSS OF POWER FOLLOWED.NO RESPONSE TO FULL ACCELERATOR PUSH. MOTOR POWER SHUT DOWN & ONLY ELECTRIC POWER ALLOWED US TO LIMP OFF THE ROAD, HEADED UPHILL AT MAX SPEED OF 10 MPH. VEHICLE TAKEN TO DEALER WHO COULD NOT REPLICATE THE CONDITIONS OR "GET IT TO ACT UP" IN THE WEEK+ A HALF THE CAR WAS THERE.ODOMETER READING SHOWS 700 MI PUT ON PRESUMABLY IN EFFORT TO MAKE DIAGNOSIS.THEIR SUGGESTION WAS TO PICK UP THE VEHICLE SINCE NO DIAGNOSIS COULD BE MADE,DESPITE OUR PROTEST THAT THE CAR WAS UNSAFE TO DRIVE.CALLED FORD CUST.RELATIONSHIP CTR 800# ON SEP15 TO SEEK ASSISTANCE.CASE WAS OPENED BUT NO ACTION TAKEN.THEY CONCURRED WITH DEALER THAT NO REPAIRS WERE TO BE MADE WITHOUT DIAGNOSIS.AGAIN,WE VOICED CONCERN THAT THE CAR WAS UNSAFE.DEALER SUSPECTED THROTTLE BODY ISSUE BUT WITHOUT DIAGNOSIS INSIST THAT REPAIRS WOULD BE AT OUR COST $400-$500. 2ND OCCURRENCE WAS OCT 2 2014.WHILE DRIVING IN TRAFFIC EXPERIENCED IMMED & SUDDEN LOSS OF POWER,NO RESPONSE TO ACCELERATION ATTEMPTS,ELECTRIC POWERED LIMP OFF UPHILL ROAD AT MAX SPEED OF 10 MPH.WAS ADVISED BY DEALER NOT TO ATTEMPT STARTING THE CAR ONCE IT DIED IN EFFORT TO MAINTAIN ERROR REPORT IN SYSTEM. WE ADHERED TO THIS ADVICE AND HAD VEHICLE TOWED TO DEALER A 2ND TIME WITHOUT STARTING IT. DEALER WAS AT THE READY WITH THE PHRASE "THROTTLE BODY" AND ASKED IF WE HAD RECEIVED ANY LETTERS IN REGARDS TO SUCH.VEHICLE WAS DIAGNOSED AS HAVING CARBON BUILDUP THAT CAUSED THROTTLE BODY TO SHORT OUT. REPAIRS MADE AT OUR EXPENSE $709.NUMEROUS COMPLAINTS ARE DOCUMENTED ON THE NHTSA WEBSITE OF THROTTLE BODY ISSUES! HYBRID OWNERS HAVE REPORTED AS WELL. OWNERS WHO HAVE HAD TO PAY FOR REPAIRS OF DEFECTIVE PARTS OUT OF THEIR OWN POCKET DESERVE COMPENSATION BY FORD. *TR
NHTSA ODI #10650762
42,000 miles · Oct 21, 2014
EngineFuel/propulsion System
CAR LOST POWER WHILE TRAVELING DOWN THE HIGHWAY. CAR WAS TOWED TO THE DEALER, WHO HAS TOLD ME THE THROTTLE BODY NEEDS TO BE REPLACED. THIS WILL COST ME ROUGHLY $500. THE THROTTLE BODY ISSUE IS WELL DOCUMENTED. IT HAS BEEN INVESTIGATED BY THE NHTSA (ACTION NUMBER PE13003). FORD DOESN'T WANT TO CALL IT A RECALL AND THE NHTS…
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CAR LOST POWER WHILE TRAVELING DOWN THE HIGHWAY. CAR WAS TOWED TO THE DEALER, WHO HAS TOLD ME THE THROTTLE BODY NEEDS TO BE REPLACED. THIS WILL COST ME ROUGHLY $500. THE THROTTLE BODY ISSUE IS WELL DOCUMENTED. IT HAS BEEN INVESTIGATED BY THE NHTSA (ACTION NUMBER PE13003). FORD DOESN'T WANT TO CALL IT A RECALL AND THE NHTSA DOES NOT CALL IT A RECALL. FORD HAS AGREED TO FIX ABOUT 1.6 MILLION CARS UNDER "CONSUMER SATISFACTION PROGRAM" 13N03. UNFORTUNATELY FOR ME, THE CONSUMER SATISFACTION PROGRAM IS VIN SPECIFIC. WHILE MANY 2010 FORD FUSIONS ARE COVERED, MY VEHICLE IS NOT. *TR
NHTSA ODI #10649032
65,000 miles · Sep 30, 2014
EngineVehicle Speed Control
INTERMITTENTLY LOSE RESPONSE FROM THROTTLE. HAPPENS ON START UP AS WELL AS WHILE DRIVING. CAR WILL NOT GO OVER 45 MPH. YOU HAVE TO PULL OVER SHUT OFF THE CAR FOR 5 SECONDS TURN IT BACK ON AND IT WILL WORK UNTIL IT HAPPENS AGAIN. MAY GO DAYS BETWEEN INCIDENT BUT HAS HAPPENED 5 TIMES IN ONE DAY. I WOULD NOT FEEL SAFE WITH THE…
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INTERMITTENTLY LOSE RESPONSE FROM THROTTLE. HAPPENS ON START UP AS WELL AS WHILE DRIVING. CAR WILL NOT GO OVER 45 MPH. YOU HAVE TO PULL OVER SHUT OFF THE CAR FOR 5 SECONDS TURN IT BACK ON AND IT WILL WORK UNTIL IT HAPPENS AGAIN. MAY GO DAYS BETWEEN INCIDENT BUT HAS HAPPENED 5 TIMES IN ONE DAY. I WOULD NOT FEEL SAFE WITH THE FAMILY IN THE CAR. THE WRENCH DOES COME ONE RIGHT BEFORE THIS HAPPENS. DEALERSHIP CONFIRMED BAD THROTTLE BODY. WILL NOT COVER THE COST OF REPAIR. CURRENTLY DISPUTING WITH FORD. *TR
NHTSA ODI #10640085
75,000 miles · Aug 14, 2014
EnginePower TrainVehicle Speed Control
I WAS DRIVING AT ABOUT 30 MPH WHEN A YELLOW WRENCH LIGHT ICON CAME ON. THE CAR STOPPED ACCELERATING, AND IT SEEMED LIKE ONLY THE ELECTRICAL POWER FROM THE BATTERY WAS KEEPING IT GOING. I HAD JUST EXITED A BUSY FREEWAY WHERE PEOPLE WERE GOING 65 MPH AND HIGHER, AND IF I HAD NOT JUST HAPPENED TO EXIT I FEAR I WOULD HAVE HAD AN ACC…
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I WAS DRIVING AT ABOUT 30 MPH WHEN A YELLOW WRENCH LIGHT ICON CAME ON. THE CAR STOPPED ACCELERATING, AND IT SEEMED LIKE ONLY THE ELECTRICAL POWER FROM THE BATTERY WAS KEEPING IT GOING. I HAD JUST EXITED A BUSY FREEWAY WHERE PEOPLE WERE GOING 65 MPH AND HIGHER, AND IF I HAD NOT JUST HAPPENED TO EXIT I FEAR I WOULD HAVE HAD AN ACCIDENT. *TR
NHTSA ODI #10622328
67,000 miles · Jul 23, 2014
EnginePower Train
DRIVING DOWN THE HIGHWAY AT 55 MPH, THE CAR SUDDENLY LOST POWER AND STARTED DECELERATING. A WRENCH LIGHT CAME ON IN THE DASHBOARD. I PULLED THE CAR ONTO THE SHOULDER OF THE ROAD AND TURNED IT OFF FOR A FEW MINUTES. WHEN I RESTARTED THE CAR IT SEEMED FINE SO I CONTINUED TO DRIVE TOWARD MY DESTINATION. ALMOST FIFTEEN MILES LATER T…
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DRIVING DOWN THE HIGHWAY AT 55 MPH, THE CAR SUDDENLY LOST POWER AND STARTED DECELERATING. A WRENCH LIGHT CAME ON IN THE DASHBOARD. I PULLED THE CAR ONTO THE SHOULDER OF THE ROAD AND TURNED IT OFF FOR A FEW MINUTES. WHEN I RESTARTED THE CAR IT SEEMED FINE SO I CONTINUED TO DRIVE TOWARD MY DESTINATION. ALMOST FIFTEEN MILES LATER THE CAR SUDDENLY LOST POWER AGAIN AND THIS TIME I WAS TRAVELING ON A TWO LANE ROAD GOING ABOUT 40 MPH. THIS TIME THE WRENCH LIGHT CAME ON AS WELL AS THE CHECK ENGINE LIGHT. AFTER PULLING OVER AND RESTARTING THE CAR THIS TIME THE CHECK ENGINE LIGHT STAYED ON FOR THE NEXT DAY OR TWO. WE TOOK THE CAR TO THE FORD DEALERSHIP A FEW DAYS LATER AFTER THIS OCCURRED FOUR TIMES IN TWO WEEKS. WE LEARNED THERE WAS A RECALL ON THE ELECTRONIC THROTTLE BODY THAT CAUSES THIS PROBLEM FOR THE FORD FUSION BUT NOT FOR THE HYBRID VERSION. THIS PART IS NOT PART OF THE HYBRID SYSTEM AND SHOULD BE REPLACED ON ALL HYBRIDS AS WELL AS REGULAR FUSIONS. WE PAID $509 FOR THE REPAIR. *TR
NHTSA ODI #10615570
107,543 miles · Sep 20, 2013
EngineFuel/propulsion SystemVehicle Speed Control
VEHICLE SUDDENLY LOST POWER AND WAS UNRESPONSIVE. DASHBOARD INDICATED "DOUBLE WRENCH" WARNING. UPON COASTING TO THE SIDE OF THE ROAD, VEHICLE WAS ABLE TO BE REACTIVATED AND DROVE NORMALLY FROM THIS POINT. *TR
NHTSA ODI #10544587
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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