IllustrationBACK PASSENGER DOOR HINGE RUSTED AND JUST FELL APART. FORD SAID TO JUST LEAVE IT SINCE WE DON'T USE THAT DOOR VERY MUCH AT ALL.
2010 Ford Fusion Hybrid
Owner reports · Recalls · Investigations
More warning signs than most Fusion Hybrid years
Owner complaints for the 2010 Ford Fusion Hybrid are substantially higher than the model-year median of 65.
About this comparison →How this year compares
Owner complaints by model year
Compare all Fusion Hybrid years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
100–25K
3625–50K
8950–75K
8675–100K
110100–150K
44150K+
375 reports with mileage · 133 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Steering. Review the 138 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 135 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes. Review the 79 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
9 crash reports0 fire reports2 injury reports
Structure complaints
11 reports3 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…
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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.
SUMMARY: I HAVE TWO COMPLAINTS. 1) TAKATA RECALL, FORD SENT ME THE NOTICE IN 2016 AND FORD MECHANIC SHOP SAID THAT FORD HAD NOT MADE ANY REPLACEABLE AIR BAGS THESE PAST THREE YEARS. I JUST CALLED THIS WEEK 8/13/18 DUE TO ANOTHER RECALL NOTICE AND AGAIN NO AIRBAGS HAD BEEN MADE. 2) DOOR LATCH STOP WORKING AND THERE WAS A RECALL…
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
WHEN THE BATTERY INSTANTLY DIED, I WAS LOCKED IN THE CAR AND HAD TO WAIT TILL THE BATTERY BUILT UP BEFORE I COULD REMOVE MYSELF FROM THE CAR. THE DOORS WOULD NOT OPEN. RECENTLY, I COULD NOT GET OUT OF THE DRIVERS SIDE DOOR BECAUSE THE LATCH INSIDE WOULD NOT OPEN THE DOOR, I HAD TO ROLL DOWN THE WINDOW AND REACH OUT TO OPEN THE D…
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WHEN THE BATTERY INSTANTLY DIED, I WAS LOCKED IN THE CAR AND HAD TO WAIT TILL THE BATTERY BUILT UP BEFORE I COULD REMOVE MYSELF FROM THE CAR. THE DOORS WOULD NOT OPEN. RECENTLY, I COULD NOT GET OUT OF THE DRIVERS SIDE DOOR BECAUSE THE LATCH INSIDE WOULD NOT OPEN THE DOOR, I HAD TO ROLL DOWN THE WINDOW AND REACH OUT TO OPEN THE DOOR. THE MECHANIC CALLED FORD AND THEY SAID THEY HAD MANY PROBLEMS WITH THE PLASTIC PIN IN THE LATCH BREAKING IN MANY OF THE VEHICLES AND COMMONLY HAVE TO BE REPLACED. THIS IS UNACCEPTABLE IN CASE OF AN EMERGENCY.
THE DRIVER-SIDE INTERIOR DOOR LATCH STOP WORKING AND I COULDN'T GET OUT OF THE CAR! THIS MALFUNCTION HAPPENED IN A VERY MUNDANE MANNER. AS I WAS DOING REGULAR ERRANDS, IN AND OUT OF THE CAR ON FRIDAY, AUGUST 5, 2016, ON MY THIRD ERRAND STOP, THE DOOR LATCH BROKE. I REALLY DIDN'T NOTICE A "SNAP" OR ANY KIND OF "BREAKING SOUND." I…
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THE DRIVER-SIDE INTERIOR DOOR LATCH STOP WORKING AND I COULDN'T GET OUT OF THE CAR! THIS MALFUNCTION HAPPENED IN A VERY MUNDANE MANNER. AS I WAS DOING REGULAR ERRANDS, IN AND OUT OF THE CAR ON FRIDAY, AUGUST 5, 2016, ON MY THIRD ERRAND STOP, THE DOOR LATCH BROKE. I REALLY DIDN'T NOTICE A "SNAP" OR ANY KIND OF "BREAKING SOUND." I DON'T KNOW IF THE BREAK OCCURRED WHILE I WAS DRIVING OR NOT. I WAS STOPPED/PARKED IN SHOPPING CENTER PARKING LOT WHEN I NOTICED THIS PROBLEM. AT FIRST I PANICKED AND WAS QUITE AFRAID. I CALLED MY BOYFRIEND AND HE CALMED ME DOWN AND INSTRUCTED ME ON HOW TO SIMPLY ROLL DOWN (ELECTRIC) WINDOW AND REACH OUT AND THEN OPEN DOOR FROM EXTERIOR. THEN, HE TOLD ME TO ROLL WINDOW UP BY LEAVING IGNITION ON AND. THIS WORKED. SO I BEEN USING MY CAR LIKE THIS UNTIL I COULD GET IT FIXED. I DID SOME RESEARCH AND LEARNED OF THE THOUSANDS OF DOOR LATCH RECALLS ON OTHER FORD FUSION MODELS. WHEN I CALLED FORD THEY SAID MY MODEL YEAR, 2010, IS NOT INCLUDED IN THE RECALL. I WILL ONLY HAVE TO PAY $100 DEDUCTIBLE BECAUSE REPAIR IS COVERED UNDER EXTENDED WARRANTY. I DON'T THINK I SHOULD HAVE TO PAY ANYTHING SINCE FORD KNOWS THEY ARE HAVING VARIOUS DOOR LATCH MSL FUNCTIONS. THIS IS MY COMPLAINT. I CLOSE BY SAYING THAT I HAVE REALLY LOVED MY FORD FUSION HYBRID AND CONSIDERING GETTING NEWER OR NEW MODEL. HOWEVER, I BELIEVE, GIVEN THE THOUSANDS OF PROBLEMS WITH DOOR LATCHES, GIVEN THE SAFETY ISSUES, FORD SHOULD REPLACE THEM ALL. THERE IS NO ATTACHMENT AS A PHOTO WOULDN'T DEMONSTRATE THE MALFUNCTION.
MY SUNROOF EXPLODED OUTWARDS WHILE I WAS DRIVING ON THE HIGHWAY. I HAD JUST LEFT THE BEACH, SO THE EXTERIOR WAS VERY HOT AND THE INTERIOR WAS VERY COLD WITH A/C RUNNING. I THOUGHT SOMETHING HAD FALLEN OUT OF THE SKY UNTIL I SAW THE GLASS WAS BOWED OUTWARDS.
THE DRIVER SIDE DOOR WOULD NOT OPEN WHEN PULLING THE LATCH FROM INSIDE THE VEHICLE, THE DOOR WOULD NOT OPEN. THE FAILURE WAS RECURRING. THE VEHICLE WAS TAKEN TO A FORD REPAIR SHOP FOR REPLACEMENT, DRIVER ONLY ABLE TO EXIT VEHICLE BY OPENING WINDOW AND USING OUTSIDE DOOR HANDLE. VEHICLE STATIONERY. PROBLEM MENTIONED ON INTERNET …
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THE DRIVER SIDE DOOR WOULD NOT OPEN WHEN PULLING THE LATCH FROM INSIDE THE VEHICLE, THE DOOR WOULD NOT OPEN. THE FAILURE WAS RECURRING. THE VEHICLE WAS TAKEN TO A FORD REPAIR SHOP FOR REPLACEMENT, DRIVER ONLY ABLE TO EXIT VEHICLE BY OPENING WINDOW AND USING OUTSIDE DOOR HANDLE. VEHICLE STATIONERY. PROBLEM MENTIONED ON INTERNET BY OTHER DRIVERS SINCE 2006
WHILE EXITING THE VEHICLE, THE LEFT-FRONT INTERIOR DOOR HANDLE BROKE ON IT'S LOWER-LEFT CORNER . BECAUSE OF THE BREAKAGE, THE DOOR WILL ONLY LOCK WITH THE INTERIOR DOOR LOCK. PRESSING THE LOCK BUTTON ON THE KEY FOB LOCKS ALL DOORS EXCEPT THE LEFT-FRONT.
TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. THE CONTACT STATED THAT THE FRONT DRIVER SIDE INTERIOR DOOR HANDLE FAILED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE DOOR HANDLE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WA…
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TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. THE CONTACT STATED THAT THE FRONT DRIVER SIDE INTERIOR DOOR HANDLE FAILED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE DOOR HANDLE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 75,000.
TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. THE CONTACT STATED THAT THE DRIVER'S SIDE FRONT INTERIOR DOOR HANDLE BECAME DETACHED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE FAILURE COULD NOT BE DIAGNOSED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE.…
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TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. THE CONTACT STATED THAT THE DRIVER'S SIDE FRONT INTERIOR DOOR HANDLE BECAME DETACHED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE FAILURE COULD NOT BE DIAGNOSED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE.
Official recalls
0No recalls in this snapshot.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
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.