NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes complaints
79 reportsClear category filter115,000 miles · May 17, 2018
Service Brakes
LEFT HOUSE ONE MORNING ABS LIGHT CAME ON AND LITTLE TO NO BRAKES. CAME BACK SLOWLY TO THE HOUSE. WAITED FIVE MINUTES TRIED AGAIN. AGAIN BRAKE PEDAL WENT TO THE FLOOR. WAITED 2 HOURS AND DROVE TO MY MECHANIC 2 MILES AWAY USING BACK ROADS. MECHANIC WHO IS RIGHT ON A HIGHWAY WENT TO TAKE IT FOR A DRIVE. NO BRAKES. AFTER CHECK…
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LEFT HOUSE ONE MORNING ABS LIGHT CAME ON AND LITTLE TO NO BRAKES. CAME BACK SLOWLY TO THE HOUSE. WAITED FIVE MINUTES TRIED AGAIN. AGAIN BRAKE PEDAL WENT TO THE FLOOR. WAITED 2 HOURS AND DROVE TO MY MECHANIC 2 MILES AWAY USING BACK ROADS. MECHANIC WHO IS RIGHT ON A HIGHWAY WENT TO TAKE IT FOR A DRIVE. NO BRAKES. AFTER CHECKING CODES IT WAS DETERMINED THAT IT NEEDED NEE ABS MODULE AND BRAKE BOOSTER. MY UNDERSTANDING IS THIS HAS BECOME A VERY SERIOUS PROBLEM THAT SHOULD BE RECALLED. HAD I MADE IT TO HIGHWAY AND HAD THIS HAPPEN AT INTERSECTION IT COULD HAVE BEEN A CRITICALLY SERIOUS SITUATION. NOW I AM SPENDING $2264 ON A FIX THAT SOME HAVE SAID DOES NOT HELP THE SITUATION. CAN WE PLEASE HOLD FORD ACCOUNTABLE FOR THESE ISSUES? THIS SHOULD BE A RECALL. DO I EVEN KNOW THE PARTS I AM BUYING WONT FAIL IN THE FUTURE OR WORSE WILL I BE SELLING A FUTURE DEATH TRAP TO A STRANGER.
NHTSA ODI #11096634
Mileage unknown · Apr 7, 2018
Service Brakes
WHEN DRIVING - INTERMITTENTLY WARNINGS STATING BRAKE SYSTEM FAILURE THEN LOSES ALL BRAKE FUNCTION FORCING USE OF EMERGENCY BRAKE- HAS HAPPENED ROUGHLY 6 TIMES DROPPED VEHICLE OFF AT FORD THEY HAVE HAD IT FOR 5 DAYS AND STILL HAVE NO IDEA HOW TO REPAIR IT
NHTSA ODI #11083723
105,000 miles · Mar 17, 2018
Service Brakes
WHILE DRIVING ON CITY STREET APPROX 45MPH, BRAKE LIGHT ILLUMINATED ALONG WITH CHECK BRAKE SYSTEM AND SERVICE ADVANCE TRAC. OBSERVED DRAMATICALLY REDUCED BRAKING POWER. HAD TO USE EMERGENCY BRAKE TO SAFELY CONTROL VEHICLE. PULLED OVER, CHECKED VEHICLE AN OBSERVED NO APPARENT LEAKS. BRAKE FLUID WAS SLIGHTLY LOW. TOPPED IT OFF. …
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WHILE DRIVING ON CITY STREET APPROX 45MPH, BRAKE LIGHT ILLUMINATED ALONG WITH CHECK BRAKE SYSTEM AND SERVICE ADVANCE TRAC. OBSERVED DRAMATICALLY REDUCED BRAKING POWER. HAD TO USE EMERGENCY BRAKE TO SAFELY CONTROL VEHICLE. PULLED OVER, CHECKED VEHICLE AN OBSERVED NO APPARENT LEAKS. BRAKE FLUID WAS SLIGHTLY LOW. TOPPED IT OFF. RESTARTED VEHICLE AND DROVE SHORT DISTANCE HOME WITH NO IMPROVEMENT. SYMPTOMS APPEAR SIMILAR TO EXISTING REPORTS ON EARLIER MODEL FUSIONS EXCEPT THAT I DID NOT ENGAGE ABS PRIOR TO OCCURRENCE.
NHTSA ODI #11079935
120,000 miles · Feb 26, 2018
Service Brakes
DRIVER WAS APPROACHING A STOPLIGHT ON A RESIDENTIAL STREET WITH A 35 MPH SPEED LIMIT. THE LIGHT TURNED YELLOW THEN RED AND DRIVER APPLIED BRAKES TO STOP AT THE LIGHT. THE BRAKES COMPLETELY FAILED AND DRIVER PROCEEDED THROUGH THE RED LIGHT INTERSECTION. DRIVER SLOWED ENOUGH A BLOCK LATER AND PULLED INTO THE OPEN GRASS FIELD NE…
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DRIVER WAS APPROACHING A STOPLIGHT ON A RESIDENTIAL STREET WITH A 35 MPH SPEED LIMIT. THE LIGHT TURNED YELLOW THEN RED AND DRIVER APPLIED BRAKES TO STOP AT THE LIGHT. THE BRAKES COMPLETELY FAILED AND DRIVER PROCEEDED THROUGH THE RED LIGHT INTERSECTION. DRIVER SLOWED ENOUGH A BLOCK LATER AND PULLED INTO THE OPEN GRASS FIELD NEXT TO THE POST OFFICE BEFORE FINALLY COMING TO A GRADUAL STOP. TWO WARNING LIGHTS APPEARED ON THE DASHBOARD AT THE TIME OF FAILURE. AFTER TURNING THE POWER OFF THEN BACK ON AGAIN THE BRAKES WORKED PERFECTLY NORMAL AGAIN AND THE WARNING LIGHTS DID NOT COME BACK ON. THE CAR WAS TAKEN TO THE LOCAL FORD DEALERSHIP AND THEY DROVE THE CAR AND CHECKED IT FOR QUITE SOME TIME, HOWEVER, THEY FOUND NOTHING WRONG WITH IT. THEY DID NOTICE THAT SOME ERROR CODES HAD INDEED TRIPPED IN THE PAST, BUT AGAIN, COULDN'T FIND ANY PROBLEMS AT ALL WITH THE BRAKE SYSTEM ($120 LATER).
NHTSA ODI #11075135
126,121 miles · Feb 5, 2018
Service BrakesUnknown Or Other
DECEMBER 31, 2018 ' WHILE DRIVING THROUGH CITY, I ATTEMPTED TO USE THE BRAKES AND THEY DID NOT RESPONSE. I WAS ABLE TO CUT THE ENGINE AND PULL OVER TO THE SIDE OF THE ROAD WITH SPOUSE AND CHILDREN IN VEHICLE. ERROR MESSAGE STATING ABS BRAKE SYSTEM WAS NOT RESPONDING AND A FALSE POSITIVE TIRE SENSOR. JANUARY 2, 2018 ' TOOK CAR…
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DECEMBER 31, 2018 ' WHILE DRIVING THROUGH CITY, I ATTEMPTED TO USE THE BRAKES AND THEY DID NOT RESPONSE. I WAS ABLE TO CUT THE ENGINE AND PULL OVER TO THE SIDE OF THE ROAD WITH SPOUSE AND CHILDREN IN VEHICLE. ERROR MESSAGE STATING ABS BRAKE SYSTEM WAS NOT RESPONDING AND A FALSE POSITIVE TIRE SENSOR. JANUARY 2, 2018 ' TOOK CAR INTO DEALERSHIP. TECHNICIANS UNABLE TO REPLICATE PROBLEM THOUGH THEY FOUND THE ERROR CODE IN SYSTEM. TECHNICIAN REPLACED BRAKES, CALIPERS, AND RESET ERROR CODE. JANUARY 27, 2018 ' SAME ERROR MESSAGE OCCURRED WITH BRAKES FAILING IN APARTMENT PARKING LOT. CAR PARKED AND ERROR MESSAGE WENT AWAY. JANUARY 31, 2018 ' SAME ERROR MESSAGE OCCURRED AND ADDED AN ADVANCETRAC SERVICE ERROR MESSAGE. BRAKES FAILED TO WORK. UPON RESEARCHING ISSUE WITH VEHICLE, I CAME ACROSS A CONSUMER REPORT WHICH DESCRIBES OUR PROBLEM EXACTLY. CALLED DEALERSHIP AND CURRENTLY WORKING AT TRYING TO SOLVE PROBLEM. DEALERSHIP STATED IF IT WAS A SOFTWARE UPDATE, THEY WOULDN'T CHARGE FOR THE LABOR INVOLVED TO UPDATE IT. IF SOFTWARE UPDATE FAILED TO SOLVE THE PROBLEM, THEY WOULD CHARGE FOR ASSESSMENT, PARTS, AND LABOR TO REPAIR. DO NOT HAVE A RECORD OF RECEIVING MAILING ABOUT THE REPAIR PROBLEM FOR THIS ISSUE AS THE VEHICLE WAS PURCHASED IN 2013.
NHTSA ODI #11067010
43,200 miles · Feb 2, 2018
Service Brakes
REAR BRAKE CALIPERS AND ROTORS RUSTED EXCESSIVELY FAST, REQUIRING A FULL REAR BRAKE JOB AT 42,300 MILES. EMERGENCY BRAKE AND EXCESSIVE RUST WAS CAUSING FRICTION AND SOUND, WHICH LED TO THE BRAKE INSPECTION. FAULTY DESIGN WHERE REAR BRAKES NEED REPLACEMENT AFTER SUCH AS SHORT PERIOD OF TIME. WHEN I TOLD FORD DEALERSHIP OF THIS…
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REAR BRAKE CALIPERS AND ROTORS RUSTED EXCESSIVELY FAST, REQUIRING A FULL REAR BRAKE JOB AT 42,300 MILES. EMERGENCY BRAKE AND EXCESSIVE RUST WAS CAUSING FRICTION AND SOUND, WHICH LED TO THE BRAKE INSPECTION. FAULTY DESIGN WHERE REAR BRAKES NEED REPLACEMENT AFTER SUCH AS SHORT PERIOD OF TIME. WHEN I TOLD FORD DEALERSHIP OF THIS ISSUE - REAR BRAKES WERE "SNAPPING" WHEN FIRST MOVING, I WAS TOLD THAT ALL FUSIONS HAVE THIS RUST BUILDUP ISSUE AND THAT IT WAS COMMON. TOOK IT INTO DEALERSHIP AND THEY JUST SHRUGGED.
NHTSA ODI #11066629
139,000 miles · Dec 30, 2017
Service Brakes
WHEN STOPPING OR DRIVING THE BRAKE LIGHTS COME ON SERVICE TRAC MESSAGE APPEARS ALARMS GO OFF AND THERE IS NO BRAKES AT ALL. A FEW TIMES YOU CAN TURN CAR OFF TURN IT BACK ON AGAIN AND THEN THE BRAKES WORK BUT RECENTLY THEY WOUKD WORK AT ALL HAD CAR TOWED TO LOCAL FORD DEALERSHIP WAS CHARGED 140.00 TO RESET THE PCM THEY SAID COMPU…
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WHEN STOPPING OR DRIVING THE BRAKE LIGHTS COME ON SERVICE TRAC MESSAGE APPEARS ALARMS GO OFF AND THERE IS NO BRAKES AT ALL. A FEW TIMES YOU CAN TURN CAR OFF TURN IT BACK ON AGAIN AND THEN THE BRAKES WORK BUT RECENTLY THEY WOUKD WORK AT ALL HAD CAR TOWED TO LOCAL FORD DEALERSHIP WAS CHARGED 140.00 TO RESET THE PCM THEY SAID COMPUTER COMMUNICATION FAILER. TODAY 24 HOURS AFTER GETTING CAR BACK WENT TO STOO AT A STOP SIGN AND NO BRAKES AND ALL THE ALARMS CAME ON AGAIN I TURNED THE CAR OFF TURNED IT ON AND BRAKES WORKED BIT I DROVE IT STRAIGHT BACK TO DEALERSHIP. THIS ISN'T NORMAL AND A HUGE SAFETY ISSUE I HAD MY DAUGHTER IN THE CAR AS WELL. I CANT SEE HOW FORD CAN ALLOW THIS TO NOT BE A COVERED ISSUE AND HOW THEY ARE OK WITH COMPLETE BRAKE FAILURE. I DON'T FEEL SAFE IN THIS CAR AT ALL.
NHTSA ODI #11057639
92,000 miles · Dec 1, 2017
Service Brakes
THE ABS BRAKE SYSTEM CUT OUT COMPLETELY THE EVENING OF 11/29/17. THE DASHBOARD LIT UP WITH WARNING LIGHTS AND BRAKE PEDAL WAS NOT FUNCTIONING. I WAS TRAVELING 10-15 MPH AND THANKFULLY WAS ABLE TO PULL OVER USING THE PARKING BRAKE. I WAS ABLE TO TURN OFF AND RESTART THE CAR. THE BRAKE SYSTEM THEN FUNCTIONED NORMALLY. I CAREFULLY …
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THE ABS BRAKE SYSTEM CUT OUT COMPLETELY THE EVENING OF 11/29/17. THE DASHBOARD LIT UP WITH WARNING LIGHTS AND BRAKE PEDAL WAS NOT FUNCTIONING. I WAS TRAVELING 10-15 MPH AND THANKFULLY WAS ABLE TO PULL OVER USING THE PARKING BRAKE. I WAS ABLE TO TURN OFF AND RESTART THE CAR. THE BRAKE SYSTEM THEN FUNCTIONED NORMALLY. I CAREFULLY DROVE HOME AND TOOK THE CAR IN FOR SERVICE THE NEXT MORNING. THE DEALERSHIP SAYS I HAVE TO REPLACE THE CONTROL MODULE AND SOLENOID, WITH AN ESTIMATE OF $2,000-3,000. HOPEFULLY, THAT WILL FIX THE PROBLEM LONG-TERM. IF THE INCIDENT HAD HAPPENED ON THE HIGHWAY, IT COULD HAVE BEEN FATAL. *JS
NHTSA ODI #11051724
60,000 miles · Oct 2, 2017
Service Brakes
VEHICLE HAD BRAKE FAILURE WHILE IN OPERATION ON OCT. 1, 2017. SUDDEN LOSS OF RESPONSE TO PRESSURE ON THE BRAKE PEDAL, EXTREME DIFFICULTY BRING VEHICLE TO A STOP. OCCURRED WHILE IN MOTION WHILE DRIVING STRAIGHT ON A CITY STREET. CHECK BRAKE LIGHT, ABS WARNING, AND SKID WARNING LIGHTS ALL CAME ON. THIS COULD BE A LIFE THREATENING…
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VEHICLE HAD BRAKE FAILURE WHILE IN OPERATION ON OCT. 1, 2017. SUDDEN LOSS OF RESPONSE TO PRESSURE ON THE BRAKE PEDAL, EXTREME DIFFICULTY BRING VEHICLE TO A STOP. OCCURRED WHILE IN MOTION WHILE DRIVING STRAIGHT ON A CITY STREET. CHECK BRAKE LIGHT, ABS WARNING, AND SKID WARNING LIGHTS ALL CAME ON. THIS COULD BE A LIFE THREATENING HAZARD HAD BRAKE FAILURE OCCURRED IN DECELERATION FROM HIGH SPEED OR DURING A CRITICAL TRAFFIC SITUATION. INJURY OR DEATH WOULD HAVE BEEN IMMINENT FROM A VEHICLE CRASH OR COLLISION. SERVICE CENTER CLAIMS THIS WAS A FAILURE OF BOTH THE ABS CONTROL MODULE AND CONTROL MODULE VALVE. MANY VERY SIMILAR DESCRIPTIONS OF COMPLAINTS ABOUT BRAKE FAILURE ARE FOUND FOR THE 2010 FORD FUSION HYBRID USING AN ON-LINE SEARCH, INCLUDING OBVIOUS RISKS FOR COLLISION, CRASHES, AND INJURIES. THIS NEEDS TO BE RECALLED AND REPAIRED IMMEDIATELY.
NHTSA ODI #11031391
71,000 miles · Sep 16, 2017
Service Brakes
BRAKES STOPPED WORKING WHILE DRIVING ON A CITY STREET. EXTREME PRESSURE ON THE PEDAL WAS REQUIRED TO SLOW THE CAR.
NHTSA ODI #11023775
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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