NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes complaints
79 reportsClear category filter110,705 miles · Jul 27, 2017
Service Brakes
POWER BRAKING FUNCTION FAILED AS I PULLED FROM CURB AND STARTED DRIVING DOWN MY RESIDENTIAL STREET. INSTRUMENT PANEL BRAKE WARNING LIGHTS ON CAME ON AND VERY HEAVY PRESSURE ON BRAKE PEDAL REQUIRED TO STOP CAR AS I APPROACHED A STOP SIGN. FORD SERVICE SHOP DIAGNOSED PROBLEM TO BE A FAILED ABS MODULE. THE CAR HAS ONLY 110705 MILES…
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POWER BRAKING FUNCTION FAILED AS I PULLED FROM CURB AND STARTED DRIVING DOWN MY RESIDENTIAL STREET. INSTRUMENT PANEL BRAKE WARNING LIGHTS ON CAME ON AND VERY HEAVY PRESSURE ON BRAKE PEDAL REQUIRED TO STOP CAR AS I APPROACHED A STOP SIGN. FORD SERVICE SHOP DIAGNOSED PROBLEM TO BE A FAILED ABS MODULE. THE CAR HAS ONLY 110705 MILES ON IT. THE REPAIR COST $765.09 FOR PART PLUS $471.83 FOR LABOR AND FEES. THIS COMPONENT FAILURE COULD HAVE BEEN EXTREMELY DANGEROUS AS HIGHWAY SPEED.
NHTSA ODI #11010949
89,000 miles · Jul 26, 2017
Service Brakes
TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. WHEN ATTEMPTING TO APPLY THE BRAKES, THE VEHICLE FAILED TO STOP UNLESS THE BRAKE PEDAL WAS DEPRESSED AGGRESSIVELY TO THE FLOORBOARD. THE CONTACT TOOK THE VEHICLE TO THE SUTTON FORD DEALER WHERE THE BRAKE BOOSTER WAS REPLACED. THE CONTACT STATED THAT THE FAILURE RECURRED TWICE AND T…
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TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. WHEN ATTEMPTING TO APPLY THE BRAKES, THE VEHICLE FAILED TO STOP UNLESS THE BRAKE PEDAL WAS DEPRESSED AGGRESSIVELY TO THE FLOORBOARD. THE CONTACT TOOK THE VEHICLE TO THE SUTTON FORD DEALER WHERE THE BRAKE BOOSTER WAS REPLACED. THE CONTACT STATED THAT THE FAILURE RECURRED TWICE AND THE DEALER REASSEMBLED THE NEW BRAKE BOOSTER UNTIL THE BRAKES FUNCTIONED PROPERLY. THE FAILURE RECURRED AGAIN AND THE CONTACT RELOCATED SOME TIME AFTERWARDS. THE CONTACT TOOK THE VEHICLE TO THE EARNHARD FORD DEALER WHO ALSO REPLACED THE BRAKE BOOSTER, BRAKE HARNESS, AND COMPUTER MODULE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE IN REFERENCE TO THE FIRST OCCURRENCE AND ASSISTED WITH THE REPAIR. THE MANUFACTURER WAS NOT MADE AWARE OF THE RECURRING FAILURES. THE APPROXIMATE FAILURE MILEAGE WAS 89,000.
NHTSA ODI #11010775
126,332 miles · May 18, 2017
Electronic Stability Control (esc)Service BrakesUnknown Or Other
I WAS JUST DRIVING ALONG ON A CITY STREET GOING ABOUT 40 MPH, AND ALL OF A SUDDEN ALL THE DASHBOARD LIGHTS LIT UP, AND I COULDN'T BREAK VERY EASILY. I WAS IN THE MIDDLE OF TRAFFIC, AND I WAS WORRIED SOMEONE WAS GOING TO HIT ME, OR I WASN'T GOING TO BE ABLE TO BREAK IF SOMEONE CUT ME OFF. MY CAR HAD BEEN SO RELIABLE UNTIL THAT …
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I WAS JUST DRIVING ALONG ON A CITY STREET GOING ABOUT 40 MPH, AND ALL OF A SUDDEN ALL THE DASHBOARD LIGHTS LIT UP, AND I COULDN'T BREAK VERY EASILY. I WAS IN THE MIDDLE OF TRAFFIC, AND I WAS WORRIED SOMEONE WAS GOING TO HIT ME, OR I WASN'T GOING TO BE ABLE TO BREAK IF SOMEONE CUT ME OFF. MY CAR HAD BEEN SO RELIABLE UNTIL THAT MOMENT. MY CAR DIDN'T BREAK THE WAY IT ALWAYS DID. IT TOOK A LOT MORE PRESSURE TO BREAK THAN NORMAL, AND THE BREAKING WAS VERY DELAYED. I HAD A FEW VERY CLOSE CALLS, BEFORE I COULD PULL OVER. IT WAS SCARY! THE DEALERSHIP HAD TO REPLACE MY ABS MODULE AND MY HYDRAULIC CONTROL UNIT, WHICH WAS VERY EXPENSIVE. I KNOW THE NHTSA IS LOOKING INTO MANY COMPLAINTS OF THE SAME ISSUE FOR 2010 FORD FUSIONS. IF OTHER VEHICLES ARE HAVING THE SAME ISSUE, THIS SHOULD BE A RECALL!
NHTSA ODI #10986304
80,000 miles · Mar 6, 2017
Service Brakes
THE BRAKES TOTALLY FAILED. THE PEDAL WENT TO THE FLOOR. THE SYSTEM DID NOT FAIL OVER TO THE PURELY MECHANICAL MODE. THE CAR SIMPLY HAD TO COAST TO A STOP. AFTER THE CAR WAS TURNED OFF AND RESTARTED THE BRAKES WORKED BUT BLOGS ARE SAYING THIS CAN HAPPEN AGAIN WITHOUT WARNING. THREE MECHANICS SAY THERE IS NOTHING WRONG WITH T…
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THE BRAKES TOTALLY FAILED. THE PEDAL WENT TO THE FLOOR. THE SYSTEM DID NOT FAIL OVER TO THE PURELY MECHANICAL MODE. THE CAR SIMPLY HAD TO COAST TO A STOP. AFTER THE CAR WAS TURNED OFF AND RESTARTED THE BRAKES WORKED BUT BLOGS ARE SAYING THIS CAN HAPPEN AGAIN WITHOUT WARNING. THREE MECHANICS SAY THERE IS NOTHING WRONG WITH THE MASTER CYLINDER, BRAKE LINES, CALIPERS, ETC. ONE SAYS IT MIGHT BE THE ABS UNIT, ANOTHER SAYS IT MIGHT BE THE SOFTWARE. THE DEALERSHIP SEEMS TO NOT KNOW WHAT IS WRONG. TWO MECHANICS HAVE DISAGREED ON WHAT THE PROBLEM IS, YOU HAVE AN OPEN INVESTIGATION ON 2008-9 MODELS BUT THIS APPEARS TO BE HAPPENING ON 2010S AND NEWER MODELS AS WELL. WE DO NOT KNOW IF OUR CAR IS SAFE TO DRIVE AND FORD APPEARS TO NOT HAVE A FIX FOR THE PROBLEM. INDEED, THEY APPEAR TO NOT EVEN BE ACKNOWLEDGING THE PROBLEM AS FAR AS I CAN TELL. THE CAR HAS BEEN IN THE SHOP SINCE THIS HAPPENED. IT IS NOW AT HOME SITTING...IT WOULD BE GOOD TO HAVE A FIX SO WE CAN DRIVE IT.
NHTSA ODI #10958799
125,319 miles · Feb 20, 2017
Service Brakes
CATASTROPHIC BRAKE FAILURE AT 50 MPH WHILE DECELERATING. RECEIVED BRAKE LIGHT FOLLOWED BY COMPLETE BRAKE FAILURE. PEDAL WENT TO FLOOR AND WAS SUBSEQUENTLY UNRESPONSIVE. ATTEMPTED TO PUMP, NO LUCK. CAR REQUIRED EMERGENCY BRAKE TO STOP NARROWLY AVOIDING COLLISION. CAR IS CURRENTLY RESIDING AT MOYER FORD DEALERSHIP IN FOLEY, …
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CATASTROPHIC BRAKE FAILURE AT 50 MPH WHILE DECELERATING. RECEIVED BRAKE LIGHT FOLLOWED BY COMPLETE BRAKE FAILURE. PEDAL WENT TO FLOOR AND WAS SUBSEQUENTLY UNRESPONSIVE. ATTEMPTED TO PUMP, NO LUCK. CAR REQUIRED EMERGENCY BRAKE TO STOP NARROWLY AVOIDING COLLISION. CAR IS CURRENTLY RESIDING AT MOYER FORD DEALERSHIP IN FOLEY, AL. DEALER STATES TO ME THAT THIS WAS A "BRAKE PEDAL ASSEMBLY FAILURE." AWAITING TROUBLESHOOTING CODES FROM DEALER.
NHTSA ODI #10955595
177,000 miles · Feb 6, 2017
Service Brakes
BRAKE FAILURE OCCURRED WITH NO WARNING ON CITY STREET WHILE CAR WAS TRAVELING STRIAGHT. FORTUNATELY, THERE WAS NO TRAFFIC PRESENT AND THE EMERGENCY BRAKE WAS USED TO SLOW THE CAR YO A STOP. AFTER RESTARTING, THE DASH "ABS" AND "BRAKE PROBLEM" LIGHTS ILLUMINATED. THE CAR FROM THIS POINT HAD VIRUTUALLY ZERO BRAKING AND THE BRAKE P…
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BRAKE FAILURE OCCURRED WITH NO WARNING ON CITY STREET WHILE CAR WAS TRAVELING STRIAGHT. FORTUNATELY, THERE WAS NO TRAFFIC PRESENT AND THE EMERGENCY BRAKE WAS USED TO SLOW THE CAR YO A STOP. AFTER RESTARTING, THE DASH "ABS" AND "BRAKE PROBLEM" LIGHTS ILLUMINATED. THE CAR FROM THIS POINT HAD VIRUTUALLY ZERO BRAKING AND THE BRAKE PEDAL WENT ALMOST TO THE FLOOR. THE CAR WAS TOWED TO A FORD DEALER FOR INSPECTION, IT WAS DETERMINED THAT THE ABS MODULE HAD GONE BAD AND NEEDED REPLACEMENT. ALTHOUGH THE PART CAN BE REPLACED, IT WON'T FIX THE PROBLEM. IT APPEARS THE ABS MODULE DESIGN AND BRAKE SYSTEM LOGIC FOR THE FUSION IS FLAWED. EXAMINATION OF THE BRAKING SYSTEM SCHEMATICS INDICATES THERE IS NO OVERRIDE FOR THE SYSTEM IF THE ABS MODULE FAILS. WHEN THIS OCCURS, AS IT DID FOR US, THE CAR'S BRAKES COMPETE WITH THE ABS SYSTEM CAUSING AN ALMOST COMPLETE LOSS OF BRAKING. OUR FAMILY WAS FORTUNATE THAT WE WERE NOT TRAVELING ON A BUSY STREET OR HIGHWAY. THE POTENTIAL FOR DAMAGE AND INJURY WAS SIGNIFICANTLY HIGH, NOT JUST TO MY FAMILY BUT TO OTHERS AS WELL. GIVEN THE AGE OF THIS VEHICLE (2010), IT IS HIGHLY LIKELY THAT THE FREQUENCY OF THESE EVENTS WILL INCREASE. THANK YOU FOR YOUR ASSISTANCE IN THIS MATTER.
NHTSA ODI #10949938
69,800 miles · Dec 24, 2016
Service Brakes
I WAS DRIVING HOME FROM WORK IN HOUSTON, TX AND SUDDENLY THE BRAKES FAILED FOR THE 2ND TIME IN A WEEK. THE CAR WAS ON, DROVE AND STEERED FINE, BUT THERE WERE NO POWER BRAKES. IT WAS AS IF A MANUAL TRANSMISSION CAR HAD STALLED, BUT EVEN WORSE. AN ERROR LIGHT CAME ON THE LEFT PANEL SAYING "CHECK BRAKE SYSTEM" AND THE PARKING BRAK…
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I WAS DRIVING HOME FROM WORK IN HOUSTON, TX AND SUDDENLY THE BRAKES FAILED FOR THE 2ND TIME IN A WEEK. THE CAR WAS ON, DROVE AND STEERED FINE, BUT THERE WERE NO POWER BRAKES. IT WAS AS IF A MANUAL TRANSMISSION CAR HAD STALLED, BUT EVEN WORSE. AN ERROR LIGHT CAME ON THE LEFT PANEL SAYING "CHECK BRAKE SYSTEM" AND THE PARKING BRAKE LIGHT WAS ON. I WAS ABLE TO QUICKLY PULL OVER. I PUT IT IN PARK, TURNED THE CAR OFF, AND THEN IMMEDIATELY STARTED IT UP. ALL WAS FINE WITH NO LIGHTS OR BELLS. I CALLED FORD AND EXPLAIN THE PROBLEM AND THEY ADVISED ME TO TAKE TO THE FORD DEALER FOR SERVICING. THEY'VE, OF COURSE, NEVER HEARD OF THIS PROBLEM AND CAN'T BELIEVE IT HAPPENED. IT SOUNDS TO ME LIKE A COMPUTER / ELECTRONIC PROBLEM. FORD KEPT THE CAR FOR 2 DAYS IN THEIR GARAGE AND THEY DROVE IT AROUND AND RUN THEY DIAGNOSTICS AND THEY SAID THEY COULDN'T FIND OUT ANY CODE OR PROBLEM AND THEY CANNOT HELP. I TOOK THE CAR OUT AND DROVE FOR 3 DAYS AND IT WAS FINE BUT ON THE 4TH DAY THE SAME PROBLEM AGAIN. BREAK FAILED TO WORK AND COME UP WITH 'AN ERROR LIGHT CAME ON THE LEFT PANEL SAYING "CHECK BRAKE SYSTEM" AND THE PARKING BRAKE LIGHT WAS ON'. FORD ARE NOT WILLING TO HELP AND THEIR GARAGE CANNOT HELP EITHER BUT THERE IS KNOWN ISSUE WITH THIS MODEL. PLEASE READ NOT FROM AUTOMOTIVE FORD: HTTP://WWW.AUTOMOTIVEWORLD.COM/ANALYSIS/80719-US-FORD-TO-FIX-FAULTY-BRAKE-SOFTWARE-ON-HYBRIDS/
NHTSA ODI #10937349
56,000 miles · Oct 29, 2016
Electrical SystemService Brakes
THIS IS THE THIRD TIME OUR CAR WILL BE GOING TO THE DEALERSHIP FOR A SERIOUS BRAKE ISSUE. THE FIRST TIME IT OCCURRED WAS IN SEPTEMBER OF 2015. THE VEHICLE WAS IN MOTION ON A RESIDENTIAL STREET WHEN THE CAR BRAKES STOPPED FUNCTIONING AS USUAL. THE DRIVER HAD TO SLAM ON THE BRAKES TO GET THE CAR TO STOP. THE CHECK BRAKE AND SERVIC…
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THIS IS THE THIRD TIME OUR CAR WILL BE GOING TO THE DEALERSHIP FOR A SERIOUS BRAKE ISSUE. THE FIRST TIME IT OCCURRED WAS IN SEPTEMBER OF 2015. THE VEHICLE WAS IN MOTION ON A RESIDENTIAL STREET WHEN THE CAR BRAKES STOPPED FUNCTIONING AS USUAL. THE DRIVER HAD TO SLAM ON THE BRAKES TO GET THE CAR TO STOP. THE CHECK BRAKE AND SERVICE LIGHTS CAME ON. THE BRAKES NO LONGER FUNCTIONED PROPERLY. THE DEALER WAS UNABLE TO REPLICATE THE ISSUE. IT HAPPENED AGAIN IN MAY OF 2016 WHEN THE CAR STARTED IN THE DRIVEWAY. AN INDEPENDENT MECHANIC WAS ABLE TO REPLICATE THE PROBLEM, WHICH WAS PRINTED OUT AND TAKEN TO THE FORD DEALERSHIP. THE DEALERSHIP WAS ABLE TO ISOLATE THE PROBLEM THIS TIME AND FIX IT. THE CAR WAS FUNCTIONAL AGAIN. TODAY, THE ISSUE HAPPENED YET AGAIN. AS THE CAR STARTED WHILE STATIONARY, THE CAR DINGED AND THE CHECK BRAKE AND SYSTEM LIGHTS CAME ON. FEARING A USER ERROR, THE DRIVER RESTARTED THE CAR AND IT SEEMED FINE. AS THE DRIVER DROVE DOWN THE RESIDENTIAL BLOCK, THE BRAKES BECAME UNRESPONSIVE AND THE SYSTEM LIGHTS CAME BACK ON. THE DRIVER HAD TO PRESS VERY HARD ON THE BRAKES TO AVOID RUNNING A STOP SIGN AND INTO ONCOMING TRAFFIC ON A NEIGHBORING STREET. THE CAR WAS TOWED TO THE DEALER.
NHTSA ODI #10920011
115,000 miles · Aug 21, 2016
Service Brakes
I WAS DRIVING AT ABOUT 45MPH ON A CITY STREET AND A BICYCLIST PULLED IN FRONT OF MY CAR. I HAD TO SLAM ON THE BRAKES TO AVOID HITTING HIM. I WAS ABLE TO AVOID AN ACCIDENT, BUT THE ABS LIGHT CAME ON AND THE BRAKES WERE NOT RESPONDING AS USUAL. I HAD TO PUSH DOWN ALL THE WAY ON THE BRAKE PEDAL FOR THE CAR TO SLOW AT ALL. I WAS TOL…
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I WAS DRIVING AT ABOUT 45MPH ON A CITY STREET AND A BICYCLIST PULLED IN FRONT OF MY CAR. I HAD TO SLAM ON THE BRAKES TO AVOID HITTING HIM. I WAS ABLE TO AVOID AN ACCIDENT, BUT THE ABS LIGHT CAME ON AND THE BRAKES WERE NOT RESPONDING AS USUAL. I HAD TO PUSH DOWN ALL THE WAY ON THE BRAKE PEDAL FOR THE CAR TO SLOW AT ALL. I WAS TOLD THAT BECAUSE I SLAMMED ON THE BRAKES IT CAUSED AN INTERNAL FAULT WITH THE ABS MODULE. THE SERVICE DEPARTMENT DID NOT SEEM CONCERNED THAT THE BRAKES HAD FAILED AND I WAS TOLD THAT SLAMMING ON THE BRAKES COULD TYPICALLY CAUSE THIS TYPE OF FAILURE WITH THE COMPUTER SYSTEM.
NHTSA ODI #10897492
64,093 miles · May 26, 2016
Service Brakes
I WAS DRIVING TO WORK, WHICH DOES NOT REQUIRE FOR ME TO TAKE THE HIGHWAY, AND AT A FOUR-WAY STOP I TRIED TO STOP MY 2010 FORD FUSION HYBRID CAR BY USING THE BRAKE PEDAL AND IT DID NOT STOP THE CAR AT ALL, BUT ITS PUMP-ACTION WAS STILL THERE. LUCKILY THERE WERE NO CARS AT THE FOUR-WAY STOP. IF THERE WERE CARS THERE, I COULD HAVE…
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I WAS DRIVING TO WORK, WHICH DOES NOT REQUIRE FOR ME TO TAKE THE HIGHWAY, AND AT A FOUR-WAY STOP I TRIED TO STOP MY 2010 FORD FUSION HYBRID CAR BY USING THE BRAKE PEDAL AND IT DID NOT STOP THE CAR AT ALL, BUT ITS PUMP-ACTION WAS STILL THERE. LUCKILY THERE WERE NO CARS AT THE FOUR-WAY STOP. IF THERE WERE CARS THERE, I COULD HAVE GOTTEN INTO A CAR ACCIDENT, EVEN WORSE IF I WAS ON THE HIGHWAY. WHEN THE BRAKE ISSUE OCCURRED, THE FOLLOWING TWO SYSTEM ERROR CODES APPEARED ON MY DASHBOARD: 1.) "(!) BRAKE CHECK BRAKE SYSTEM" AND (2) "SERVICE ADVANCETRAC". AT THE SAME TIME THAT THESE TWO SYSTEM ERROR CODES APPEARED, THERE WERE FIVE WARNING LIGHTS THAT APPEARED: 1.) ADVANCETRAC/TRACTION CONTROL OFF LIGHT (AKA ORANGE-YELLOW CAR W/ TIRE MARKS OFF) 2.) ADVANCETRAC/TRACTION CONTROL (AKA ORANGE-YELLOW CAR W/ TIRE MARKS SYMBOL) 3.) BRAKE SYSTEM WARNING LIGHT (AKA RED !(P) BRAKE) 4.) ANTI-LOCK BRAKE SYSTEM (AKA "ABS" SYMBOL) WARNING LIGHT 5.) ON THE UPPER LEFT-HAND CORNER TO THE LEFT OF THE SYSTEM ERROR CODE "(!) BRAKE CHECK BRAKE SYSTEM" A LITTLE (!) BRAKE SYMBOL APPEARED. I HAVE A PICTURE OF ALL OF THESE SYSTEM ERROR CODES AND LIGHTS. SO, THEN I USED THE EMERGENCY BRAKE HANDLE STICK TO STOP THE CAR AND THAT HELPED ONLY TO SLOW THE CAR DOWN BY 20%, BUT NOT ENOUGH TO STOP THE CAR. I LEFT THE EMERGENCY BRAKE ON AND DID NOT USE THE ACCELERATOR PEDAL TO SLOW DOWN THE CAR. THE CAR SLOWED DOWN TO A SLOW STOP AFTER 1-2 MINUTES AFTER DRIVING OVER SOME SPEED BUMPS DRIVING AT 30-35 MPH. WHEN IT STOPPED, I RESTARTED THE CAR TO SEE IF THAT WOULD FIX THE ISSUE AND IT DID NOT. SO I PRESSED THE ACCELERATOR PEDAL VERY LIGHTLY WITHOUT USING THE EMERGENCY BRAKE AND GOT TO A SPEED OF LESS THAN 10 MPH TO GET TO WORK BECAUSE I WAS ALMOST THERE. WHEN I SLOWLY DRIFTED INTO MY WORK'S PARKING LOT, I IMMEDIATELY USED THE EMERGENCY BRAKE AGAIN TO GET THE CAR TO STOP.
NHTSA ODI #10871006
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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