NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
508 reports93,000 miles · Aug 14, 2018
Engine
TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. WHILE DRIVING 25 MPH, THE VEHICLE STALLED AND THE SERVICE VEHICLE SOON WARNING INDICATORS ILLUMINATED. THE CONTACT TURNED THE VEHICLE OFF AND, ONCE RESTARTED, RESUMED NORMAL OPERATION. THE VEHICLE WAS TAKEN TO THE DEALER (KISTLER FORD SALES INC., 5555 CENTRAL AVE, TOLEDO, OH 43615,…
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TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. WHILE DRIVING 25 MPH, THE VEHICLE STALLED AND THE SERVICE VEHICLE SOON WARNING INDICATORS ILLUMINATED. THE CONTACT TURNED THE VEHICLE OFF AND, ONCE RESTARTED, RESUMED NORMAL OPERATION. THE VEHICLE WAS TAKEN TO THE DEALER (KISTLER FORD SALES INC., 5555 CENTRAL AVE, TOLEDO, OH 43615, (419)-531-9911), BUT WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN ANY RECALLS. THE FAILURE MILEAGE WAS 93,000.
NHTSA ODI #11119872
70,810 miles · Aug 14, 2018
Power Train
THE WARNING LIGHT CAME ON FOR THE THROTTLE CONTROL/POWERTRAIN MALFUNCTION. THE VEHICLE JERKS FORWARD AS SOON AS I TAKE MY FOOT OFF THE BRAKE. IF I PUT IT IN REVERSE, THE VEHICLE JERKS BACKWARD WITHOUT ME HITTING THE GAS. THE VEHICLE WAS JUST TURNING INTO A PARKING GARAGE WHEN THIS OCCURRED.
NHTSA ODI #11119859
60,750 miles · Aug 11, 2018
Engine
THROTTLE BODY DEFECT. VEHICLE LOST POWER ON HIGHWAY AND WOULD NOT GO OVER 50 MPH. THE VEHICLE WENT INTO SAFETY MODE, ALSO KNOWN AS "LIMP HOME MODE". DEALER REPLACED THROTTLE BODY, WHICH SOLVED THE PROBLEM. THE FORD "CUSTOMER SATISFACTION PROGRAM" INVOLVING THE DEFECTIVE THROTTLE BODY DOES NOT COVER HYBRID VEHICLES LIKE MINE,…
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THROTTLE BODY DEFECT. VEHICLE LOST POWER ON HIGHWAY AND WOULD NOT GO OVER 50 MPH. THE VEHICLE WENT INTO SAFETY MODE, ALSO KNOWN AS "LIMP HOME MODE". DEALER REPLACED THROTTLE BODY, WHICH SOLVED THE PROBLEM. THE FORD "CUSTOMER SATISFACTION PROGRAM" INVOLVING THE DEFECTIVE THROTTLE BODY DOES NOT COVER HYBRID VEHICLES LIKE MINE, EVEN THOUGH IT HAS THE SAME DEFECTIVE PART. I COMPLAINED TO FORD AND THEY CREATED CASE #CAS15334188.
NHTSA ODI #11119386
88,000 miles · Aug 9, 2018
Service Brakes
MY BREAKS IN MY 2010 FORD FUSION HYBRID STOPPED WORKING A COUPLE SECONDS AFTER STARTING THE CAR (ALONG WITH A BEEPING ALERT AND DISPLAY ON DASHBOARD TO CHECK BREAKS). FORTUNATELY I WAS IN A PARKING LOT AND GOING AT A SLOW SPEED. I WAS ABLE TO PULL TO THE SIDE AND STOP. I TURNED THE VEHICLE OFF. WHEN TURNING THE VEHICLE BACK ON T…
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MY BREAKS IN MY 2010 FORD FUSION HYBRID STOPPED WORKING A COUPLE SECONDS AFTER STARTING THE CAR (ALONG WITH A BEEPING ALERT AND DISPLAY ON DASHBOARD TO CHECK BREAKS). FORTUNATELY I WAS IN A PARKING LOT AND GOING AT A SLOW SPEED. I WAS ABLE TO PULL TO THE SIDE AND STOP. I TURNED THE VEHICLE OFF. WHEN TURNING THE VEHICLE BACK ON THE ALERTS WERE GONE AND BREAKS WORKED. I HAD THE BREAKS CHECKED AND WAS TOLD THEY WERE FINE. ABOUT A MONTH WENT PAST, I WAS COMING TO A STOP AT A LIGHT ON A CITY STREET AND MY BREAKS SUDDENLY WENT OUT (ALONG WITH AN ALERT DISPLAY OF CHECK BREAKS). LUCKILY NO CARS WERE IN FRONT OF ME SO I WAS ABLE TO MAKE A RIGHT TURN AND PULL TO THE SIDE UNTIL MY CAR CAME TO A COMPLETE STOP. I TURNED THE CAR OFF AND ON AND BREAKS AGAIN WORKED FINE AND ALL WARNING LIGHTS OFF. WITH PLANS TO TAKE THE VEHICLE TO THE FORD DEALER AFTER WORK I PARKED. AFTER ABOUT 8 HOURS WITH THE VEHICLE BEING OFF I RETURNED TO MY CAR. I TURNED ON THE VEHICLE AND THE BREAK ALERT WAS BACK AND I HAD NO FUNCTIONAL BREAKS. THIS TIME WHEN I CONTINUED TO TURN THE CAR ON AND OFF THE ALERT DID NOT GO AWAY AND THE BREAKS DID NOT RETURN.
NHTSA ODI #11118838
149,058 miles · Jul 31, 2018
Service BrakesSteering
TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. WHILE DRIVING 55 MPH, THE SERVICE POWER STEERING NOW AND ELECTRONIC CONTROL SYSTEM WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. AN INDEPENDENT MECHANIC DIAGNOSED THAT THE TRANSMISSION FRICTION ELEMENT G PERFORMANCE AND THE INVALID DATA RECEIVED …
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TL* THE CONTACT OWNS A 2010 FORD FUSION HYBRID. WHILE DRIVING 55 MPH, THE SERVICE POWER STEERING NOW AND ELECTRONIC CONTROL SYSTEM WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. AN INDEPENDENT MECHANIC DIAGNOSED THAT THE TRANSMISSION FRICTION ELEMENT G PERFORMANCE AND THE INVALID DATA RECEIVED FROM ABS CONTROL MODULE CODES WERE FOUND. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 149,058.
NHTSA ODI #11114967
110,000 miles · Jul 27, 2018
Electrical SystemEngineFuel/propulsion System
THE 2010 FORD FUSION HYBRID KEEPS GOING INTO "LIMP" MODE EVEN ON THE HIGHWAY. THIS CAUSES POWER LOSS AND LOSS OF ACCELERATION. THIS CAN BE AT ANYTIME. THIS KEEPS HAPPENING MORE AND MORE AND FORD DOES NOT KNOW THE CAUSE OR RESOLVE.
NHTSA ODI #11114046
116,400 miles · Jul 19, 2018
Service Brakes
LESS THAN A MINUTE AFTER STARTING THE CAR, I WAS BRAKING AND TURNING SLIGHTLY LEFT ON A SLIGHT DECLINE IN A PARKING LOT. THE BRAKE PEDAL SUDDENLY WENT SOFT, BRAKE FAILURE ALERT SOUNDED AND APPEARED ON DASHBOARD, AND PEDAL WENT ALL THE WAY TO THE FLOOR, NEVER RE-ENGAGING DESPITE PUMPING. THANKFULLY BECAUSE I WAS TRAVELING 10MPH…
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LESS THAN A MINUTE AFTER STARTING THE CAR, I WAS BRAKING AND TURNING SLIGHTLY LEFT ON A SLIGHT DECLINE IN A PARKING LOT. THE BRAKE PEDAL SUDDENLY WENT SOFT, BRAKE FAILURE ALERT SOUNDED AND APPEARED ON DASHBOARD, AND PEDAL WENT ALL THE WAY TO THE FLOOR, NEVER RE-ENGAGING DESPITE PUMPING. THANKFULLY BECAUSE I WAS TRAVELING 10MPH AT MOST, AND DESPITE MY SHOCK AND CONFUSION, I WAS ABLE TO AVOID A COLLISION, AND QUICKLY PARK IN ANOTHER SPOT. I MADE A PHONE CALL AND DECIDED TO TRY AGAIN AND UPON RESTART THE BRAKES HAD NO PROBLEMS AND I WAS ABLE TO DRIVE HOME, WITH MY ONE HAND READY TO USE THE EMERGENCY BRAKE. GIVEN THE CONDITIONS THIS FAILURE OCCURRED, I SUSPECT THE PROBLEM IS WITH THE HYDRAULIC CONTROL UNIT.
NHTSA ODI #11112290
Mileage unknown · Jul 16, 2018
Air Bags
TAKATA RECALL. IT HAS BEEN MORE THAN 2 YEARS AND A FIX HAS NOT BEEN PROVIDED. I CANNOT SELL MY CAR WITH THIS RECALL NOR CAN IT BE FIXED. MY ONLY OPTION (OTHER THAN THE HASSLE OF A RENTAL CAR) IS TO NOT HAVE ANYONE SIT IN THE FRONT PASSENGER SEAT OF MY CAR WHICH, WITH A FAMILY OF 5, IS IMPOSSIBLE TO DO LEGALLY. LUCKILY, WE HAVE A…
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TAKATA RECALL. IT HAS BEEN MORE THAN 2 YEARS AND A FIX HAS NOT BEEN PROVIDED. I CANNOT SELL MY CAR WITH THIS RECALL NOR CAN IT BE FIXED. MY ONLY OPTION (OTHER THAN THE HASSLE OF A RENTAL CAR) IS TO NOT HAVE ANYONE SIT IN THE FRONT PASSENGER SEAT OF MY CAR WHICH, WITH A FAMILY OF 5, IS IMPOSSIBLE TO DO LEGALLY. LUCKILY, WE HAVE ANOTHER VEHICLE THAN CAN FIT US ALL. A COWORKER OF MINE HAD HIS TOYOTA REPAIRED EARLIER THIS YEAR BUT FORD HAS NOT YET TO ISSUE A SOLUTION. MORE THAN 2 YEARS WITHOUT A REMEDY IS A BIT RIDICULOUS.
NHTSA ODI #11111691
92,000 miles · Jul 11, 2018
SteeringSuspension
MANY FORD FUSIONS HAVE A RECALL ON THE STEERING RACK. 2010 DOES NOT. MINE IS IN SHOP FOR REPAIR. ALSO, THE TRANSFER CASE WENT OUT. COSTLY REPAIRS. I AM NOT ABLE TO DRIVE DUE TO THE STEERING. ALREADY FIXED THE TRANSFER CASE AND SWAY BAR.
NHTSA ODI #11110814
154,016 miles · Jul 2, 2018
Steering
I EXITED MY CAR, WITH IT RUNNING, WENT INSIDE A STORE, WHEN I REENTERED MY CAR & PLACED IT IN REVERSE & BACKED OUT OF MY PARKING SPOT A RED WARNING APPEARED ON MY DASH "SERVICE POWER STEERING NOW". I THEN PLACED THE CAR IN DRIVE. THE POWER STEERING THEN COMPLETELY FAILED AND I WAS FORCED TO MUSCLE IT HOME FROM THERE. THE DASH IN…
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I EXITED MY CAR, WITH IT RUNNING, WENT INSIDE A STORE, WHEN I REENTERED MY CAR & PLACED IT IN REVERSE & BACKED OUT OF MY PARKING SPOT A RED WARNING APPEARED ON MY DASH "SERVICE POWER STEERING NOW". I THEN PLACED THE CAR IN DRIVE. THE POWER STEERING THEN COMPLETELY FAILED AND I WAS FORCED TO MUSCLE IT HOME FROM THERE. THE DASH INDICATORS NOW SAY "POWER STEERING FAULT" AFTER SOME RESEARCH I FIND THAT THERE HAS BEEN A RECALL FOR THE EXACT SAME EQUIPMENT USED IN THIS CAR, BUT NOT FOR THIS MODEL YEAR. WHY IS THERE NO RECALL FOR THIS MODEL YEAR? THIS IS AN EXTREME SAFETY ISSUE. LUCKILY I WAS NOT AT SPEED WHEN THIS FAILURE OCCURRED AS I AM NOT SURE I WOULD HAVE BEEN ABLE TO CONTROL THE VEHICLE HAD THAT HAPPENED.
NHTSA ODI #11105063
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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