NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes complaints
79 reportsClear category filter150,000 miles · May 10, 2019
Service Brakes
I HAD THE AIRBAG REPLACED BECAUSE OF THE TAKATA RECALL. THE FOLLOWING WEEK, I STARTED THE CAR AND WARNING LIGHTS CAME ON. THANKFULLY, I WAS IN A PARKING LOT THAT HAD SOME EMPTY SPACES. I APPLIED THE BRAKES AND REALIZED I HAD NONE. THE BRAKE WENT TO THE FLOOR AND NOTHING. I HAD TO USE THE EMERGENCY BRAKE TO STOP THE CAR. I THEN …
Read full complaint
I HAD THE AIRBAG REPLACED BECAUSE OF THE TAKATA RECALL. THE FOLLOWING WEEK, I STARTED THE CAR AND WARNING LIGHTS CAME ON. THANKFULLY, I WAS IN A PARKING LOT THAT HAD SOME EMPTY SPACES. I APPLIED THE BRAKES AND REALIZED I HAD NONE. THE BRAKE WENT TO THE FLOOR AND NOTHING. I HAD TO USE THE EMERGENCY BRAKE TO STOP THE CAR. I THEN STEERED TO A PARKING SPACE AND APPLIED THE EMERGENCY BRAKE TO STOP THE CAR AGAIN. I HAD TO HAVE THE CAR TOWED TO THE FORD PLACE. THEY SAID IT HAD NOTHING TO DO WITH THE AIRBAG REPAIR, BUT I CAN'T GET OVER HOW THERE WAS NO WARNING OF THE PROBLEM. THE CAR HAD DRIVEN PERFECTLY. MY SON COULD HAVE BEEN DRIVING MY CAR AND DOES NOT HAVE A LOT OF DRIVING EXPERIENCE. WE USE THE INTERSTATE ALL OF THE TIME AND I KEEP THINKING HOW I COULD HAVE BEEN IN HEAVY TRAFFIC WHEN THIS HAPPENED. PLEASE NOTE THAT I HAVE RESEARCHED THIS PROBLEM AND HAVE COME ACROSS MANY FORUMS WHERE PEOPLE ARE SAYING THE EXACT SAME THING HAPPENED TO THEM AND THEY WERE IN A FORD FUSION HYBRID! A CAR SHOULD NOT SUDDENLY LOSE ITS BRAKES! THE DEALERSHIP SAYS TWO ELECTRIC MODULES WENT OUT IN THE ABS SYSTEM AND IT'S $1,000 TO FIX THEM. THEY ALSO SAID THERE MAY BE A HYDRAULIC PROBLEM BUT "WE WON'T KNOW UNTIL WE REPLACE THE MODULES". I STILL CAN'T BELIEVE I HAD NO BRAKES IN AN INSTANT! THIS SHOULD BE A RECALL.
NHTSA ODI #11206923
122,500 miles · May 7, 2019
Service Brakes
WHILE DRIVING 20 MPH IN MY SUBURBAN NEIGHBORHOOD. BRAKES FAILED WITHOUT WARNING. THE BRAKE PEDAL TRAVEL INCREASED SIGNIFICANTLY. STOPPING REQUIRED ME TO PUMP THE BRAKE PEDAL TO THE FLOOR FORCEFULLY WHILE ALSO APPLYING THE EMERGENCY BRAKE. STOPPING DISTANCE LENGTHENED SIGNIFICANTLY. THE DEALERSHIP INFORMED ME IT WAS AN ANTILOCK B…
Read full complaint
WHILE DRIVING 20 MPH IN MY SUBURBAN NEIGHBORHOOD. BRAKES FAILED WITHOUT WARNING. THE BRAKE PEDAL TRAVEL INCREASED SIGNIFICANTLY. STOPPING REQUIRED ME TO PUMP THE BRAKE PEDAL TO THE FLOOR FORCEFULLY WHILE ALSO APPLYING THE EMERGENCY BRAKE. STOPPING DISTANCE LENGTHENED SIGNIFICANTLY. THE DEALERSHIP INFORMED ME IT WAS AN ANTILOCK BRAKING SYSTEM (ABS) HYDRAULIC CONTROL UNIT (HCU) FAILURE. COST ESTIMATE IS $1,000 TO REPLACE.
NHTSA ODI #11206124
160,755 miles · Apr 10, 2019
Service Brakes
COMPLETE BRAKE FAILURE DUE TO AN ELECTRONIC COMPONENT FAILURE. THE BRAKE PEDAL WENT ALL THE WAY TO THE FLOORBOARD. THERE WAS NO COLLISION AND THE VEHICLE CAME TO REST ON THE SHOULDER OF THE HIGHWAY. *JS
NHTSA ODI #11195431
112,580 miles · Apr 1, 2019
Service Brakes
I HAD A COMPLETE BRAKE FAILURE ON 12/18/2018 WHILE DRIVING DOWN A CITY STREET AND THE PEDAL WENT COMPLETELY TO THE FLOOR, I PUMPED FRANTICALLY WITH LITTLE OR NO RESISTANCE I TOOK THE CAR OUT OF DRIVE AND APPLIED THE EMERGENCY BRAKE AFTER REVIEWING I FOUND FORD KNEW OF THIS PROBLEM TSB-09-22-11 I ASKED FORD FOR HELP AS THIS IS A…
Read full complaint
I HAD A COMPLETE BRAKE FAILURE ON 12/18/2018 WHILE DRIVING DOWN A CITY STREET AND THE PEDAL WENT COMPLETELY TO THE FLOOR, I PUMPED FRANTICALLY WITH LITTLE OR NO RESISTANCE I TOOK THE CAR OUT OF DRIVE AND APPLIED THE EMERGENCY BRAKE AFTER REVIEWING I FOUND FORD KNEW OF THIS PROBLEM TSB-09-22-11 I ASKED FORD FOR HELP AS THIS IS A $2300 ABS MODULE FIX AND THEY STICK THEIR HEADS IN THE SAND .
NHTSA ODI #11192918
149,000 miles · Jan 2, 2019
Service Brakes
CAR WAS DRIVING FINE. I WAS DRIVING WITHIN LOW SPEED CITY LIMITS. I WAS DRIVING DOWN THE ROAD WHEN ALL OF A SUDDEN, MY CHECKADVANCETRAC LIGHT, ABS LIGHT, AND BRAKE LIGHTS ALL CAME ON. WHEN I TRIED TO SLOW DOWN FOR A STOP, THERE WERE NO BRAKES, I KEPT TRYING BUT THEN FINALLY I TRIED AGAIN AND I HAD TO SLAM DOWN ON THE BRAKES TO …
Read full complaint
CAR WAS DRIVING FINE. I WAS DRIVING WITHIN LOW SPEED CITY LIMITS. I WAS DRIVING DOWN THE ROAD WHEN ALL OF A SUDDEN, MY CHECKADVANCETRAC LIGHT, ABS LIGHT, AND BRAKE LIGHTS ALL CAME ON. WHEN I TRIED TO SLOW DOWN FOR A STOP, THERE WERE NO BRAKES, I KEPT TRYING BUT THEN FINALLY I TRIED AGAIN AND I HAD TO SLAM DOWN ON THE BRAKES TO EVEN GET THE CAR TO STOP. IT WAS VERY DANGEROUS, I COULDN'T STOP, IT SCARED ME. I CHECKED THE BRAKE FLUID AFTER I GOT HOME WHICH WAS FINE. I LET IT SIT, PUMPED THE BRAKES HARD, AND NOW THE BRAKES STARTED WORKING, BUT THE LIGHTS ARE STILL ON. THIS IS MY DAILY DRIVER FOR WORK AND ITS VERY SCARY. THIS ALL HAPPENED AFTER THE AIRBAGS WERE REPLACED, WHICH I HAD TO WAIT 6 MONTHS FOR. I SHOULD NOT HAVE TO DRIVE AN UNSAFE CAR. PLEASE LOOK INTO THIS. THIS IS ONGOING PROBLEM WHEN YOU RESEARCH ONLINE. THERE IS EVEN A FORD BULLETIN CODE ATTACHED BUT FORD DEALERSHIPS ARE NOT WILLING TO FIX THE PROBLEM. THE NUMBER IS TSB-09-22-11.
NHTSA ODI #11164677
450 miles · Dec 6, 2018
Service Brakes
I WAS DRIVING AND MAKING A TURN. BRAKES WENT VERY SOFT AND HAD TO PRESS BRAKE PEDAL TO FLOOR TO GET IT TO STOP. BRAKE WARNING LIGHT AND ANTI-SKID LIGHTS ILLUMINATED ON DASHBOARD. TOOK A LONG TIME TO BRING CAR TO A STOP. THIS OCCURRED PRIOR TO TAKING THE CAR IN FOR THE TAKATA AIR BAG RECALL. THE CAR HAD BEEN SITTING AND THE BATTE…
Read full complaint
I WAS DRIVING AND MAKING A TURN. BRAKES WENT VERY SOFT AND HAD TO PRESS BRAKE PEDAL TO FLOOR TO GET IT TO STOP. BRAKE WARNING LIGHT AND ANTI-SKID LIGHTS ILLUMINATED ON DASHBOARD. TOOK A LONG TIME TO BRING CAR TO A STOP. THIS OCCURRED PRIOR TO TAKING THE CAR IN FOR THE TAKATA AIR BAG RECALL. THE CAR HAD BEEN SITTING AND THE BATTERY HAD DIED AND THEY SAID THAT WAS THE PROBLEM. INSTALLED NEW BATTERY, HAD AIR BAG REPLACED, AND THE ISSUE OCCURRED AGAIN. I AM STILL DRIVING THE VEHICLE BUT DO NOT FEEL THAT IT IS SAFE. WHEN WILL YOUR COMPANY AND FORD TAKE THIS SERIOUSLY? WHEN SOMEONE DIES LIKE WITH THE AIR BAG RECALL. THIS NEEDS TO BE DIAGNOSED AND FORD NEEDS TO PAY FOR THE REPAIRS DUE TO ALL THE COMPLAINTS.
NHTSA ODI #11156524
120,014 miles · Nov 29, 2018
Service Brakes
I TURNED ON MY CAR AND MY CHECK ENGINE LIGHT CAME ON. I TURNED LEFT OUT OF MY DRIVEWAY ONTO THE MAIN ROAD GOING 10-15MPH. AFTER DRIVING ABOUT 5 SECONDS ON THE ROAD, MY ABS LIGHT, TRACTION LIGHT, ADVANCED TRACTION LIGHT, AND BRAKE LIGHT ALL WENT ON. I PULLED OFF TO THE RIGHT-HAND LANE AND PRESSED MY BRAKES TO STOP THE CAR. THE CA…
Read full complaint
I TURNED ON MY CAR AND MY CHECK ENGINE LIGHT CAME ON. I TURNED LEFT OUT OF MY DRIVEWAY ONTO THE MAIN ROAD GOING 10-15MPH. AFTER DRIVING ABOUT 5 SECONDS ON THE ROAD, MY ABS LIGHT, TRACTION LIGHT, ADVANCED TRACTION LIGHT, AND BRAKE LIGHT ALL WENT ON. I PULLED OFF TO THE RIGHT-HAND LANE AND PRESSED MY BRAKES TO STOP THE CAR. THE CAR DID NOT STOP AT ALL WHEN I PRESSED THE BRAKE PEDAL. I SLAMMED MY PEDAL TO THE GROUND AND THE PEDAL FELT SOFT. THE CAR SLOWLY CAME TO A STOP RIGHT AS I CAME TO THE INTERSECTION. I TURNED AROUND AND WENT BACK INTO MY PARKING SPOT. I HAD TO PUSH THE BRAKE PEDAL TO THE FLOOR TO STOP THE CAR. I TOWED MY CAR INTO THE FORD DEALERSHIP AND THEY COULD NOT DIAGNOSE WHY THE BREAKS FAILED. THEY CHANGED THE BATTERY BUT THEY WERE NOT ABLE TO PROVIDE AN EXPLANATION AS TO WHY THAT WOULD CAUSE THE BREAKS TO FAIL.
NHTSA ODI #11154872
165,100 miles · Nov 13, 2018
Service Brakes
AS I WAS DRIVING INTO A PARKING LOT, THE BRAKES FELT LIKE THEY WOULDN'T WORK AND THE WARNING LIGHT AND BELL WENT ON, BUT ULTIMATELY THE CAR STOPPED, BUT I HAD TO PRESS BRAKE PEDAL TO THE FLOOR HARD TO STOP THE CAR. I HAD THE CAR TOWED TO MIDAS. THEY SAID IT WAS AN ELECTRONIC OR COMPUTER PROBLEM AND SUGGESTED I TAKE IT TO A DEALE…
Read full complaint
AS I WAS DRIVING INTO A PARKING LOT, THE BRAKES FELT LIKE THEY WOULDN'T WORK AND THE WARNING LIGHT AND BELL WENT ON, BUT ULTIMATELY THE CAR STOPPED, BUT I HAD TO PRESS BRAKE PEDAL TO THE FLOOR HARD TO STOP THE CAR. I HAD THE CAR TOWED TO MIDAS. THEY SAID IT WAS AN ELECTRONIC OR COMPUTER PROBLEM AND SUGGESTED I TAKE IT TO A DEALER. I THEN HAD IT TOWED TO SAYBROOK FORD. THEY DIAGNOSED REPLACING ECU AND HCU, EVEN THOUGH THE CAR DIDN'T DEMONSTRATE THE PROBLEM TO THEM.I FOUND ON LINE A TECHNICAL SERVICE BULLETIN FROM FORD (TSB-09-22-11) AND A BRAKE SYSTEM UPDATE SPECIFIED BY FORD'S CUSTOMER SATISFACTION PROGRAM 10B13. WHEN I TOLD THE FORD DEALER, HE STATED THERE IS NO RECALL ON THE BRAKES. I EXPLAINED TO HIM AGAIN, BUT HE WAS NOT INTERESTED IN HEARING ABOUT THIS. I CALLED THE NATIONAL FORD OFFICE AND SPOKE WITH SOMEONE WHO SUGGESTED I CONTACT YOU. CONSUMER REPORTS SAID IF THE 2010 FORD FUSION HYBRID WAS BUILT BEFORE OCTOBER 17, 2009, THE DEALER SHOULD PERFORM THE BRAKE SYSTEM SOFTWARE UPDATE. MY CAR WAS BUILT ON APRIL 22, 2009 ACCORDING TO FORD, BUT THEY SAID MY CAR WASN'T COVERED. I AM COMPLAINING TO YOU AS MY CAR HAS THE EXACT PROBLEM STATED IN 10B13. PLEASE HELP. THANK YOU. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).' *PM
NHTSA ODI #11151310
80,000 miles · Oct 29, 2018
Service Brakes
INTERMITTENT SUDDEN LOSS OF BRAKING POWER, WITH SYSTEM GOING INTO "FAIL SAFE" MODE, "SERVICE ADVANCETRAC", "WRENCH", AND OTHER WARNING LIGHTS COMING ON, AND PEDAL GOING TO THE FLOOR. PRIMARILY ON INITIAL STARTING OF THE CAR, OR A FEW MOMENTS AFTER THE CAR WAS PUT INTO MOTION. THOUGH ALSO OBSERVED AT HIGHER SPEEDS. NOT RELATED…
Read full complaint
INTERMITTENT SUDDEN LOSS OF BRAKING POWER, WITH SYSTEM GOING INTO "FAIL SAFE" MODE, "SERVICE ADVANCETRAC", "WRENCH", AND OTHER WARNING LIGHTS COMING ON, AND PEDAL GOING TO THE FLOOR. PRIMARILY ON INITIAL STARTING OF THE CAR, OR A FEW MOMENTS AFTER THE CAR WAS PUT INTO MOTION. THOUGH ALSO OBSERVED AT HIGHER SPEEDS. NOT RELATED TO STEERING OR ROAD CONDITIONS. PROBLEM SEEMED TO SELF-CORRECT AFTER TURNING CAR OFF AND THEN ON AGAIN, WOULD DISAPPEAR FOR 3 TO 12 MONTHS, THEN SUDDENLY REAPPEAR WITHOUT WARNING. TOO INTERMITTENT FOR CONFIDENT DIAGNOSIS. NEARLY CAUSED AN ACCIDENT ON SEVERAL OCCASIONS.
NHTSA ODI #11143733
146 miles · Oct 27, 2018
Service BrakesStructureUnknown Or Other
3 YEARS AGO-BATTERY FAILED AND COULD NOT EXIT THE VEHICLE AT ALL, NO WARNING. 2 YEARS AGO-PLASTIC PIECE IN DOOR WHICH ALLOWS THE MANUAL DOOR OPENER TO WORK BROKE, COULD NOT EXIT DRIVER SIDE DOOR. 3 YEARS AGO - ACCELERATOR STOPPED WORKING ON HIGHWAY, FINALLY PULLED OVER AND RESTARTED CAR AND IT WORKED - DEALER SAID COULD NOT FIND…
Read full complaint
3 YEARS AGO-BATTERY FAILED AND COULD NOT EXIT THE VEHICLE AT ALL, NO WARNING. 2 YEARS AGO-PLASTIC PIECE IN DOOR WHICH ALLOWS THE MANUAL DOOR OPENER TO WORK BROKE, COULD NOT EXIT DRIVER SIDE DOOR. 3 YEARS AGO - ACCELERATOR STOPPED WORKING ON HIGHWAY, FINALLY PULLED OVER AND RESTARTED CAR AND IT WORKED - DEALER SAID COULD NOT FIND PROBLEM. ROCKER PANELS RUSTED OUT AFTER 6 YEARS - GARAGED INDOORS. HEATING SYSTEM FAILED - IT TOOK 1.5 MONTHS TO OBTAIN PARTS AND FIX VEHICLE, I WENT TO COLONIAL FORD 5 TIMES (AND HOUR EACH WAY) BECAUSE THEY SAID IT WAS FIXED 5 TIMES IN THE 1.5 MONTHS. 2018-10-25 - CHECK BRAKE SYSTEM LIGHT CAME ON - NO BRAKES GOING 65 MPH DOWN A HIGHWAY HILL FOR 5 MINUTES. POLICE GUIDED TO A HALT, RESTARTED CAR AND BRAKES WORKED. MADE IT HOME. BRAKES FAILED 3 TIMES THE NEXT DAY. FORD SAID THEY COULD NOT LOOK AT THE VEHICLE FOR 3 WEEKS BECAUSE THEY WERE SO BUSY SO I HAD TO RENT A VEHICLE. $1750 TO REPLACE BRAKE SENSORS WHICH THEY SAID COULD NOT COMMUNICATE WITH THE BRAKES.?? FIRST TIME FORD HAS BEEN ABLE TO DIAGNOSE SYSTEM.
NHTSA ODI #11143409
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.
Illustration