NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
38 reportsClear category filterMileage unknown · Jul 28, 2017
Air BagsFuel/propulsion System
TL* TAKATA RECALL. THE CONTACT OWNS A 2010 FORD FUSION HYBRID. THE CONTACT STATED THAT THERE WAS A RANDOM FUEL LEAK THAT CONTINUED TO PROGRESS. THE DEALER (FORD OF ESCONDIDO, 1717 AUTO PARK WAY, ESCONDIDO, CA 92029, (760) 745-3361) ATTEMPTED TO ORDER THE PART SEVERAL TIMES, AND HAD TWO ESTIMATED SHIPMENT DATES. THE MOST RECENT D…
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TL* TAKATA RECALL. THE CONTACT OWNS A 2010 FORD FUSION HYBRID. THE CONTACT STATED THAT THERE WAS A RANDOM FUEL LEAK THAT CONTINUED TO PROGRESS. THE DEALER (FORD OF ESCONDIDO, 1717 AUTO PARK WAY, ESCONDIDO, CA 92029, (760) 745-3361) ATTEMPTED TO ORDER THE PART SEVERAL TIMES, AND HAD TWO ESTIMATED SHIPMENT DATES. THE MOST RECENT DATE WAS AUGUST 27, 2017. THE MANUFACTURER WAS UNABLE TO PROVIDE A REASONABLE TIME FRAME TO SUPPLY THE PART TO THE DEALER. THE VEHICLE REMAINED PARKED SINCE MAY OF 2017. THE CONTACT HAD TO OBTAIN A RENTAL VEHICLE DUE TO THE DELAY FROM THE MANUFACTURER. THE MANUFACTURER WAS CONTACTED SEVERAL TIMES AND THE CONTACT WAS STILL WAITING FOR THE PART MONTHS LATER. IN ADDITION, THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 16V384000 (AIR BAGS) AND WAS UNCERTAIN AS TO WHEN THE REMEDY AND PARTS WOULD BE SUPPLIED TO THE DEALER. THE CONTACT STATED THAT THE AIR BAG OFF INDICATOR KEPT RANDOMLY ILLUMINATING WHILE WAITING FOR THE PART FROM THE MANUFACTURER. THE FAILURE MILEAGE WAS NOT AVAILABLE. VIN TOOL CONFIRMS PARTS NOT AVAILABLE. UPDATED 09/27/17*LJ THE CONSUMER STATED A NEW GAS TANK AND A NEW CAR BATTERY WERE INSTALLED IN THE VEHICLE.*JS *TR
NHTSA ODI #11011356
77,000 miles · Jul 6, 2017
Fuel/propulsion SystemPower Train
CAR SUDDENLY LOOSES POWER AT HIGHWAY SPEED. DIAGNOSED AS THROTTLE BODY FAILURE AND REPLACED BY DEALER. FORD COVERS NON HYBRID MODELS WITH REPLACEMENT AT N/C TO OWNERS BUT EXCLUDES HYBRID COVERAGE FOR SAME PART ON SAME ICE ENGINE WITH SAME SYMPTOMS. SUDDEN LOSS OF POWER AT HIGHWAY SPEEDS IS EXTREMELY DANGEROUS ESP IN URBAN TRA…
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CAR SUDDENLY LOOSES POWER AT HIGHWAY SPEED. DIAGNOSED AS THROTTLE BODY FAILURE AND REPLACED BY DEALER. FORD COVERS NON HYBRID MODELS WITH REPLACEMENT AT N/C TO OWNERS BUT EXCLUDES HYBRID COVERAGE FOR SAME PART ON SAME ICE ENGINE WITH SAME SYMPTOMS. SUDDEN LOSS OF POWER AT HIGHWAY SPEEDS IS EXTREMELY DANGEROUS ESP IN URBAN TRAFFIC SITUATION AND THIS SHOULD BE A MANDATORY RECALL.
NHTSA ODI #11003316
61,000 miles · Mar 28, 2017
Fuel/propulsion System
VEHICLE WILL NOT ACCELERATE SUDDENLY THROTTLE BODY MALFUNCTION.
NHTSA ODI #10969033
58,700 miles · Aug 15, 2016
EngineFuel/propulsion SystemPower Train
JULY 29, 2016 DRIVING HOME FROM WORK I WAS DRIVING UPHILL WHEN I NOTICED THE CAR LOSING POWER, NO AMOUNT OF PUSHING DOWN ON THE ACCELERATOR MADE A DIFFERENCE. THE CAR DID NOT STALL BUT IT COULD NOT GAIN MOMENTUM. THE SERVICE ENGINE LIGHT CAME ON. I HAD TO STOP IN THE RIGHT LANE BECAUSE THERE WAS NO SHOULDER AND THE ENGINE HAD…
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JULY 29, 2016 DRIVING HOME FROM WORK I WAS DRIVING UPHILL WHEN I NOTICED THE CAR LOSING POWER, NO AMOUNT OF PUSHING DOWN ON THE ACCELERATOR MADE A DIFFERENCE. THE CAR DID NOT STALL BUT IT COULD NOT GAIN MOMENTUM. THE SERVICE ENGINE LIGHT CAME ON. I HAD TO STOP IN THE RIGHT LANE BECAUSE THERE WAS NO SHOULDER AND THE ENGINE HAD STARTED MAKING A VERY LOUD/ROUGH SOUND. I WAITED 5 MIN AND STARTED THE CAR AGAIN. EVERYTHING LOOKED FINE, THE INDICATOR LIGHT HAD CLEARED AND ENGINE SOUNDED NORMAL. I DROVE THE REST OF THE WAY HOME WITHOUT INCIDENT. OVER THE WEEKEND THE CAR OPERATED NORMALLY. ON MONDAY 8/1/2016 ON MY WAY TO WORK THE PROBLEM STARTED AGAIN. THE CAR REMAINED OPERATIONAL BUT COULDN'T GO MORE THAN 20-30 MPH. THE HYBRID BATTERY WOULD DRAIN VERY QUICKLY AND THE REGENERATION MOTOR RAN CONSTANTLY AND SOMETIME VERY ROUGH. I MANAGED TO DRIVE IT TO MY MECHANIC. HIS DIAGNOSTIC REPORT SHOWED A P2112 CODE (THROTTLE BODY STUCK CLOSED). HE PROPOSED CLEANING THE VALVE AS A FIRST STEP BUT HE DIDN'T THINK THAT WOULD FIX THE PROBLEM. WE TRIED THAT BUT TWO DAYS LATER THE PROBLEM CAME BACK. MY MECHANIC ADVISED THAT WHILE HE COULD REPLACE THE ETB, HE WAS NOT EQUIPPED TO CALIBRATE IT AND THAT ONLY FORD COULD DO THIS WORK. HE ALSO TOLD ME THAT WHILE RESEARCHING THE PROBLEM HE'D COME ACROSS INFORMATION THAT MY PROBLEM MIGHT BE COVERED BY AN EXTENDED WARRANTY. I CALLED FORD ABOUT THE EXTENDED WARRANTY AND THEY TOLD ME THAT HYBRIDS ARE NOT COVERED BY THE WARRANTY. IT SEEMS TO ME THAT NHTSA DROPPED THE BALL ON THIS IF THE SAME PROBLEM IS HAPPENING TO HYBRID OWNERS AS IS TO NON-HYBRID OWNERS FOR VEHICLE MODELS OF THE SAME YEARS. MY VEHICLE HAD ABOUT 58,700 MILES WHEN TROUBLE STARTED. NO ONE I SPOKE TO AT FORD COULD TELL ME WHY HYBRIDS ARE NOT COVERED BY THE ETB EXTENDED WARRANTY. SEEMS TO ME NHTSA NEEDS TO RE-OPEN THEIR INVESTIGATION ON THIS ISSUE!
NHTSA ODI #10895852
114,459 miles · Jun 30, 2016
Fuel/propulsion System
THROTTLE BODY FAILED. WHILE IN MOTION ON DIVIDED 45 MPH ROAD, CAR WOULD NOT ACCELERATE. MAX SPEED 45 GOING DOWN HILL. FOUND THROTTLE BODY FAILED.
NHTSA ODI #10881895
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
85,000 miles · Jan 13, 2016
Fuel/propulsion System
WHILE DRIVING IN TRAFFIC ON A CITY STREET WHILE TRAVELING ABOUT 30 MPH THE CHECK ENGINE LIGHT WAS ON AND A WARNING MESSAGE TO "STOP SAFELY NOW" APPEARED ON THE DASH. IMMEDIATELY, THE CAR STOPPED ACCELERATING. I STILL HAD POWER - LIGHTS, RADIO, HEATER - BUT COULD NOT ACCELERATE AND THE CAR JUST COASTED. I TURNED THE KEY OFF A…
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WHILE DRIVING IN TRAFFIC ON A CITY STREET WHILE TRAVELING ABOUT 30 MPH THE CHECK ENGINE LIGHT WAS ON AND A WARNING MESSAGE TO "STOP SAFELY NOW" APPEARED ON THE DASH. IMMEDIATELY, THE CAR STOPPED ACCELERATING. I STILL HAD POWER - LIGHTS, RADIO, HEATER - BUT COULD NOT ACCELERATE AND THE CAR JUST COASTED. I TURNED THE KEY OFF AND WAS ABLE TO RESTART THE CAR, THE WARNING WAS GONE AND THEN GO ABOUT 5 CAR LENGTHS BEFORE GETTING THE WARNING AGAIN. I DROVE HOME (ABOUT 4 MILES) AND HAD TO RESTART, COAST AND STOP ABOUT 7 TIMES. I WAS DRIVING ON A ROAD WHERE THE SPEED LIMIT IS 35 MPH, MADE IT HOME AND CONTINUED TO DRIVE AROUND IN MY NEIGHBORHOOD WHERE THERE WAS NO TRAFFIC, TO SEE IF IT WOULD CONTINUE. IT HAPPENED 2 MORE TIMES. PUT THE CAR IN THE GARAGE AND CALLED WEBB FORD IN HIGHLAND, IN THE NEXT DAY. WAS ABLE TO DRIVE THE CAR 8 MILES TO THE DEALERSHIP WITH NO INCIDENT. THE CAR IS THERE NOW. HAD I BEEN DRIVING ON THE INTERSTATE, IN THE LEFT HAND LANE I COULD HAVE BEEN KILLED. I PURCHASED THIS CAR USED IN JUNE OF 2015 WITH 79,900 MILES ON IT AND HAVE HAD NO PROBLEMS UNTIL NOW. IT HAS APPROX 86,000 MILES ON IT AT THIS TIME. I LOVE THIS CAR BUT NOW AM AFRAID TO DRIVE IT. HAVE THERE BEEN ANY REPORTS OF SIMILAR INCIDENTS? IT IS A HYBRID AND I HAVE NOT SEEN ANY RECALLS.
NHTSA ODI #10820030
Mileage unknown · Dec 30, 2015
Fuel/propulsion System
HI I GOT AN EMAIL TELLING ME ABOUT MY OLDER CAR (2010 FORD FUSION SE) WHICH HAS A RECALL FOR MY CURRENT CAR (2010 FORD FUSION HYBRID) DOESN'T HAVE THE SAME RECALL BUT ITS THE SAME WONDERING WHY" FORD MOTOR COMPANY (FORD) IS RECALLING CERTAIN MODEL YEAR 2010-2011 FORD FUSION VEHICLES MANUFACTURED JULY 21, 2008, TO MARCH 4, 2011, …
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HI I GOT AN EMAIL TELLING ME ABOUT MY OLDER CAR (2010 FORD FUSION SE) WHICH HAS A RECALL FOR MY CURRENT CAR (2010 FORD FUSION HYBRID) DOESN'T HAVE THE SAME RECALL BUT ITS THE SAME WONDERING WHY" FORD MOTOR COMPANY (FORD) IS RECALLING CERTAIN MODEL YEAR 2010-2011 FORD FUSION VEHICLES MANUFACTURED JULY 21, 2008, TO MARCH 4, 2011, AND 2010-2011 MERCURY MILAN VEHICLES MANUFACTURED JULY 23, 2008, TO DECEMBER 10, 2010. THE AFFECTED VEHICLES HAVE FUEL VAPOR CANISTERS WHOSE PURGE VALVES MAY NOT OPERATE PROPERLY RESULTING IN ABNORMAL PRESSURE CHANGES IN THE FUEL TANK." *JS
NHTSA ODI #10817118
55,000 miles · Dec 11, 2015
Fuel/propulsion System
VEHICLE LOOSES ALL THROTTLE RANDOMLY WHILE MOVING (HAS HAPPENED ON FREEWAY, STREET, UPHILL, DOWNHILL AND WHILE TURNING). THE WRENCH INDICATOR DASH LIGHT COMES ON. VEHICLE MUST BE POWERED OFF AND THEN ON AGAIN TO REGAIN THROTTLE. SOMETIMES MULTIPLE RESTARTS ARE NECESSARY TO REGAIN THROTTLE. OBD CODE 2112 $07E8 THROTTLE ACTUAT…
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VEHICLE LOOSES ALL THROTTLE RANDOMLY WHILE MOVING (HAS HAPPENED ON FREEWAY, STREET, UPHILL, DOWNHILL AND WHILE TURNING). THE WRENCH INDICATOR DASH LIGHT COMES ON. VEHICLE MUST BE POWERED OFF AND THEN ON AGAIN TO REGAIN THROTTLE. SOMETIMES MULTIPLE RESTARTS ARE NECESSARY TO REGAIN THROTTLE. OBD CODE 2112 $07E8 THROTTLE ACTUATOR CONTROL SYSTEM STUCK CLOSED.
NHTSA ODI #10809673
19,000 miles · Dec 10, 2015
Fuel/propulsion System
I HAVE BEEN REQUESTING INFORMATION FROM FORD ABOUT THE RECENTLY ANNOUNCED CRACKING GAS CANISTER RECALL AFFECTING MY MODEL VEHICLE WITHOUT SUCCESS. MEDIA REPORTS THE RECALL INCLUDES 2010 VEHICLES MADE IN HERMOSILLO, MEXICO. FORD DID TELL ME THAT MINE WAS MANUFACTURED THERE AT THE END OF FEBRUARY 2010 AND DID SAY THAT MINE WAS NOT…
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I HAVE BEEN REQUESTING INFORMATION FROM FORD ABOUT THE RECENTLY ANNOUNCED CRACKING GAS CANISTER RECALL AFFECTING MY MODEL VEHICLE WITHOUT SUCCESS. MEDIA REPORTS THE RECALL INCLUDES 2010 VEHICLES MADE IN HERMOSILLO, MEXICO. FORD DID TELL ME THAT MINE WAS MANUFACTURED THERE AT THE END OF FEBRUARY 2010 AND DID SAY THAT MINE WAS NOT INCLUDED, BUT WILL NOT TELL ME WHAT PERCENTAGE OF THE VEHICLES BUILT THERE DURING FEBRUARY AND MARCH 2010 ARE INCLUDED IN THE RECALL. I HAVE BEEN CORRESPONDING WITH THEM VIA EMAIL FOR SEVERAL WEEKS NOW AND THEY CONTINUALLY EVADE ANSWERING MY CONCERN. THE COMPANY'S LAST MESSAGE SAID THE INFORMATION I AM REQUESTING IS NOT AVAILABLE. IT IS SURPRISING TO BE TOLD BY A MODERN MANUFACTURING FACILITY LIKE FORD THAT IT DOES NOT KNOW HOW MANY UNITS IT MANUFACTURED DURING A GIVEN PERIOD OF TIME AT A SPECIFIC FACILITY. WHY WOULD THEY REFUSE TO PROVIDE SUCH INFORMATION UNLESS IT WOULD REVEAL THAT ALL THE VEHICLES BUILT AT HERMOSILLO IN FEBRUARY AND MARCH 2010 CONTAIN THE DEFECT? THIS IS ESPECIALLY TROUBLING TO ME BECAUSE IT INVOLVES A FUEL ISSUE AND PUTS ONE IN MIND OF THE CORVAIR SITUATION.
NHTSA ODI #10809538
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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