NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
38 reportsClear category filter36,001 miles · Feb 10, 2014
Fuel/propulsion System
MY CAR WARRANTY EXPIRED IN LATE DECEMBER 2013. IN JANUARY I HAD AN INSTANCE INVOLVING ENGINE LIGHTS (WRENCHES ON DASH) ILLUMINATED AS I WAS DRIVING IN THE 54-60 MPH RANGE. POWER WAS REDUCED AND THE VEHICLE SLOWED DOWN BUT COULD STILL MOVE AT ABOUT 30-35 MPH. AFTER TURNING OFF THE CAR IT LATER RESUMED NORMAL OPERATION WITH THE …
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MY CAR WARRANTY EXPIRED IN LATE DECEMBER 2013. IN JANUARY I HAD AN INSTANCE INVOLVING ENGINE LIGHTS (WRENCHES ON DASH) ILLUMINATED AS I WAS DRIVING IN THE 54-60 MPH RANGE. POWER WAS REDUCED AND THE VEHICLE SLOWED DOWN BUT COULD STILL MOVE AT ABOUT 30-35 MPH. AFTER TURNING OFF THE CAR IT LATER RESUMED NORMAL OPERATION WITH THE EXCEPTION THAT I NOTICED LOWER MPG. WHEN I FIRST GOT THE CAR 41 MPG WAS THE BEST I COULD GET WHILE DRIVING TO MAXIMIZE MPG. THROUGH THE YEARS MPG WENT DOWN TO 37, STABILIZED, AND THEN IN RECENT MONTHS 35, THEN 30, ETC. I HAD TO PAY $460 TO MY LOCAL FORD DEALER TO REPLACE THE THROTTLE BODY AND TO REPROGRAM THE COMPUTER. IN LIGHT OF ALL THE PROBLEMS EXPERIENCED BY FORD VEHICLES WITH THESE THROTTLE BODIES, I BELIEVE FORD SHOULD PAY FOR THIS REPAIR, ESPECIALLY SINCE THE BUMPER TO BUMPER WARRANTY COVERAGE "TIMED OUT" (I.E. BEFORE THE 36,000 MILEAGE WAS EXCEEDED) IN LATE DECEMBER 2013. I HAD A SIMILAR EXPERIENCE WITH VW AROUND 2002 WHEN A HEATER CORE IN A PASSAT (NOTE I LIVE IN FLORIDA) WENT BAD A FEW THOUSAND MILES AFTER THE BUMPER TO BUMPER WARRANTY EXPIRED. VW SHOWED GOODWILL AND PAID THE COST OF THE REPAIR. FORD SHOULD DO THE SAME. *TR
NHTSA ODI #10563639
19,300 miles · Feb 9, 2014
Fuel/propulsion SystemService BrakesSteeringCrash
MONDAY, JAN. 27 - POWER SUDDENLY GAVE OUT WHEN ACCELERATING ON FREEWAY. SERVICE WRENCH HAD BEEN ON EARLIER THAT DAY BUT HAD GONE OFF. DIXON FORD TOLD US IT WAS OK TO DRIVE. I WAS IN LEFT LANE AND HAD TO CROSS 5 LANES TO GET TO MEDIAN. TOOK IT IN TO WALNUT CREEK FORD AND THEY "RE-FLASHED IT", SAYING NO CONCERN WAS PRESENT AT THE …
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MONDAY, JAN. 27 - POWER SUDDENLY GAVE OUT WHEN ACCELERATING ON FREEWAY. SERVICE WRENCH HAD BEEN ON EARLIER THAT DAY BUT HAD GONE OFF. DIXON FORD TOLD US IT WAS OK TO DRIVE. I WAS IN LEFT LANE AND HAD TO CROSS 5 LANES TO GET TO MEDIAN. TOOK IT IN TO WALNUT CREEK FORD AND THEY "RE-FLASHED IT", SAYING NO CONCERN WAS PRESENT AT THE TIME. THEY GAVE THE DANGEROUS CAR BACK TO US FRI, JAN 31ST 130 MILES DRIVEN IN 2ND LANE (ONE FROM CARPOOL LANE) AT 65 MPH ACCEL LIGHTLY SUDDENLY, CAR'S GAS GAVE OUT, LIKE BEFORE THE ROAD CURVED TO RIGHT. TRY TO STEER CAR RIGHT TO FOLLOW LANE AS CAR DECEL NOTICED THAT STEERING NOT RESPONDING, EVEN TO STRONGEST INPUTS (ALMOST LIKE LOCKED, LIKE CAR WAS OFF) TRIED TO HIT BRAKES, BUT PEDAL SANK TO FLOOR NO RESPONSE REGARDLESS OF PRESSURE. KEPT PRESSURE BUT CAR DID NOT SLOW BEGAN TO DRIFT PASSENGER GRABBED WHEEL ALSO AND TRIED TO PULL RIGHT. GRADUALLY STARTED TO GO RIGHT, BUT WITH EXTREME FORCE APPLIED. AFTER FORCE, WHEEL AT MOST 5 DEGREES TURN EMERGENCY BRAKE TO SLOW (NOT STOP) STEERING CORRECTIONS COULD NOT SUFFICIENTLY TURN CAR SO CAR SLAMMED INTO CONCRETE MEDIAN AT 50 MPH TIGHTENED EMERGENCY BRAKE AND CONTINUED TO PULL ON THE WHEEL SLID ALONG MEDIAN AS CAR SCREECHED CAR FINALLY STOPPED ON THE LEFT SIDE OF FREEWAY GEAR SELECTOR LOCKED IN DRIVE TURNED OFF THE ENGINE WHILE THE SELECTOR WAS STILL IN PARK. RESPONDING CHP OFFICER K. ALLEMAN ASKED US TO DRIVE CAR TO THE OTHER SIDE OF THE FREEWAY COULD NOT START CAR. TURNED KEY 3 TIMES BUT CAR REFUSED TO RESPOND. GETTING VERY HOT IN THE CAR, JUST LIKE MON, PROB 95 -100 AMBIENT TEMP AGAIN WHEN EXT. TEMP. 58 FINALLY ABLE TO SELECT NEUTRAL AND RELEASE PARKING BRAKE. CAR DID NOT START PAX&I HAD TO PULL HARD TO GET WHEEL TO TURN AT ALL INCIDENT REPORT #[XXX] OFFICER CONFIRMED BRAKES, STEERING, AND POWER WERE ALL GONE. DETAILS IN REPT. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10563626
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
94,500 miles · Sep 8, 2013
EngineFuel/propulsion SystemUnknown Or Other
I WAS TRAVELING APPROXIMATELY 55 MPH UNDER NORMAL DRIVING CONDITIONS WHEN THE CAR LOST POWER AND I WAS ABLE TO DRIFT TO SIDE OF ROAD. WRENCH LIGHT CAME ON. I WAITED A FEW MINUTES AND RESTARTED THE CAR. IT IDLED ROUGH AT FIRST BUT I WAS ABLE TO CONTINUE THE DRIVE HOME WITHOUT INCIDENT. I RESEARCHED THIS PROBLEM ON THE INTERNET…
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I WAS TRAVELING APPROXIMATELY 55 MPH UNDER NORMAL DRIVING CONDITIONS WHEN THE CAR LOST POWER AND I WAS ABLE TO DRIFT TO SIDE OF ROAD. WRENCH LIGHT CAME ON. I WAITED A FEW MINUTES AND RESTARTED THE CAR. IT IDLED ROUGH AT FIRST BUT I WAS ABLE TO CONTINUE THE DRIVE HOME WITHOUT INCIDENT. I RESEARCHED THIS PROBLEM ON THE INTERNET AND DISCOVERED THAT FORD FUSIONS OF MY YEAR AND MILEAGE WERE EXPERIENCING THIS ISSUE. THE FIRST RECOMMENDED COARSE OF ACTION WAS TO USE A THROTTLE BODY CLEANER. I DID THIS AND THE CAR SEEMED TO OPERATE FINE UNDER CONDITIONS 25 MPH. I SET OFF TO WORK ON THE 6TH AND THE CAR SHUT OFF ON ME SIX TIMES BEFORE I COULD MAKE IT TWENTY MILES AND GET BACK TO THE HOUSE. THIS IS AN OBVIOUS MANUFACTURERS DEFECT AND NEEDS TO BE HANDLED APPROPRIATELY.
NHTSA ODI #10542529
38,047 miles · Aug 25, 2013
Fuel/propulsion System
DRIVING ON TWO LANE ROAD AT NIGHT MADE LEFT TURN AND LOST THROTTLE CONTROL OF CAR. CAR WOULD DRIVE 20 MPH UNTIL I COULD GET OFF ROAD ABOUT ONE MILE. LIGHT CAME ON DASHBOARD TO PULL OF SAFELY. I STOPPED TURNED THE CAR TO OFF AND RESTARTED, IT DROVE PERFECTLY TO DEALER ABOUT 20 MILES. DIAGNOSED AS BAD THROTTLE BODY. THIS C…
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DRIVING ON TWO LANE ROAD AT NIGHT MADE LEFT TURN AND LOST THROTTLE CONTROL OF CAR. CAR WOULD DRIVE 20 MPH UNTIL I COULD GET OFF ROAD ABOUT ONE MILE. LIGHT CAME ON DASHBOARD TO PULL OF SAFELY. I STOPPED TURNED THE CAR TO OFF AND RESTARTED, IT DROVE PERFECTLY TO DEALER ABOUT 20 MILES. DIAGNOSED AS BAD THROTTLE BODY. THIS COULD BE A CATASTROPHIC PROBLEM IF HAPPENS ON INSIDE LANE OF INTERSTATE AT HIGHWAY SPEEDS. *TR
NHTSA ODI #10537117
40,100 miles · Aug 13, 2013
Fuel/propulsion SystemVehicle Speed Control
CAR PERFORMING NORMALLY THEN WRENCH SYMBOL COMES ON DASH AND CAR ACCELERATOR WOULD NOT RESPOND. LIMPED CAR OVER TO FORD DEALER ON THE HYBRID BATTERY. DEALER WHO DID NOT HAVE STAFF ENOUGH TOO LOOK AT IT FOR 2 DAYS. TOWED OVER TO DEALER NEAR ME . HEARD TODAY IT IS A BAD THROTTLE BODY AND ASSOCIATED ELECTRONICS AND GOING TO COST $6…
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CAR PERFORMING NORMALLY THEN WRENCH SYMBOL COMES ON DASH AND CAR ACCELERATOR WOULD NOT RESPOND. LIMPED CAR OVER TO FORD DEALER ON THE HYBRID BATTERY. DEALER WHO DID NOT HAVE STAFF ENOUGH TOO LOOK AT IT FOR 2 DAYS. TOWED OVER TO DEALER NEAR ME . HEARD TODAY IT IS A BAD THROTTLE BODY AND ASSOCIATED ELECTRONICS AND GOING TO COST $600-$700 TO REPLACE. LOOKING A THE INTERNET IT SURE SEEMS A LOT OF OWNERS ARE HAVING THE SAME ISSUE. THERE IS ACTUALLY A VIDEO NOW ON U-TUBE ON HOW TO REPLACE YOURSELF THERE ARE SO MANY OF THESE THROTTLE BODY'S FAILING. *TR
NHTSA ODI #10535236
51,000 miles · Jun 21, 2013
Fuel/propulsion SystemVehicle Speed Control
SUDDEN LOSS OF POWER WHILE DRIVING. VEHICLE STALLED AS I WAS ABOUT TO GET ON THE ON-RAMP TO THE INTERSTATE HIGHWAY. WAS NOT ABLE TO ACCELERATE OR MAINTAIN SPEEDS FASTER THAN 35 MPH. VEHICLE WAS TAKEN TO REPAIR SHOP AND THE PROBLEM WAS DIAGNOSED AS A FAULTY THROTTLE BODY. *TR
NHTSA ODI #10521125
30,000 miles · Jun 20, 2013
Electrical SystemEngineFuel/propulsion System
THE CAR STALLS AT VARIED SPEEDS WHICH IS A HUGE SAFETY ISSUE. I OWNED A 2010 FORD FUSION PREVIOUSLY WITH MY COMPANY FLEET VEHICLE PROGRAM, AND HAD THE SAME PROBLEM. I BROUGHT THE CAR TO THE DEALERSHIP AND IT WAS FIXED WITHOUT QUESTION. AT THAT TIME I WAS UNAWARE OF THIS BEING PART OF A BIGGER PROBLEM. IN THE FALL OF 2011, I…
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THE CAR STALLS AT VARIED SPEEDS WHICH IS A HUGE SAFETY ISSUE. I OWNED A 2010 FORD FUSION PREVIOUSLY WITH MY COMPANY FLEET VEHICLE PROGRAM, AND HAD THE SAME PROBLEM. I BROUGHT THE CAR TO THE DEALERSHIP AND IT WAS FIXED WITHOUT QUESTION. AT THAT TIME I WAS UNAWARE OF THIS BEING PART OF A BIGGER PROBLEM. IN THE FALL OF 2011, I PURCHASED A DIFFERENT 2010 FORD FUSION FROM OUR FLEET AS IT WAS BEING TURNED IN, AND THIS IS THE VEHICLE THAT I AM DISCUSSING IN THIS FORUM. IT ONLY HAS 30000 MILES ON IT, BUT IS 6 MONTHS OUT OF THE 36 MONTH BUMPER TO BUMPER WARRANTY. THE CAR STALLED ONCE, A MONTH AGO, AND THE PROBLEM SEEMED TO RECTIFY ITSELF. THEN YESTERDAY, 6/19/2013, IT STALLED 6 TIMES. MY 17 YEAR OLD DAUGHTER DRIVES THE CAR AND WAS STUCK IN THE MIDDLE OF A VERY BUSY INTERSECTION. FOR ALMOST ONE MINUTE, THE CAR WOULD NOT RESTART, BUT FINALLY DID, AND SHE WAS ABLE TO GET OUT OF THE INTERSECTION. AS I READ THE FORUMS, IT IS OBVIOUS TO ME THAT THIS IS A NATIONWIDE PROBLEM, LOOKING BACK, I'VE HAD 2 CARS WITH THE IDENTICAL PROBLEM. THE SERVICE MEN AT THE DEALERSHIP KNOW THAT THE PROBLEM IS SPECIFIC TO THE THROTTLEBODY, WHICH IS DEFECTIVE, AND THERE IS OVER A WEEK BACKLOG ON THE PARTS AS MORE AND MORE CARS ARE HAVING THE SAME ISSUE. THIS IS A DANGEROUS PROBLEM, TO LOSE POWER TO A VEHICLE IN MOTION AND FORD IS AWARE OF THIS ISSUE, YET THEY ARE TAKING NO STEPS IN ADDRESSING THE ISSUE. IT IS GOING TO COST ME $600 TO HAVE THE PART REPLACED, AS IT IS OUTSIDE THE 3 YEAR WARRANT, YET FORD KNOWS THAT THIS WAS A MODEL WIDE ISSUE WITH A DEFECTIVE CAR PART. I AM DISAPPOINTED AND ANGRY THAT A GLARING PROBLEM SUCH AS THIS IS NOT BEING ADDRESSED DUE TO FORD ATTEMPTING TO LET THE PROBLEM HOPEFULLY JUST FADE AWAY AND NOT BE TAKEN TO TASK OVER THIS ISSUE. I PRAY THAT THE NHTSA WILL STEP IN, RIGHT A WRONG, AND IN THE PROCESS PREVENT A TRAGIC ACCIDENT BEFORE IT BECOMES A REALITY. *TR
NHTSA ODI #10520838
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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