NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
508 reports80,000 miles · Oct 29, 2015
Electrical SystemService Brakes
WAS ON HIGHWAY DRIVING 60 MPH WHEN VARIOUS BRAKE WARNING STARTED FLASHING ON DASHBOARD. WARNING SAID I NEEDED TO STOP IMMEDIATELY. I SLOWED DOWN BUT BRAKES WERE NOT RESPONSIVE. I MANAGED TO FIND AN UPHILL EXIT AND GOT THE CAR TO STOP SAFELY. I TURNED THE CAR OFF, RESTARTED IT, AND THE PROBLEM DISAPPEARED. I HAVE OWNED THIS CAR S…
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WAS ON HIGHWAY DRIVING 60 MPH WHEN VARIOUS BRAKE WARNING STARTED FLASHING ON DASHBOARD. WARNING SAID I NEEDED TO STOP IMMEDIATELY. I SLOWED DOWN BUT BRAKES WERE NOT RESPONSIVE. I MANAGED TO FIND AN UPHILL EXIT AND GOT THE CAR TO STOP SAFELY. I TURNED THE CAR OFF, RESTARTED IT, AND THE PROBLEM DISAPPEARED. I HAVE OWNED THIS CAR SINCE FEB. 2010 AND HAVE NEVER HAD THIS PROBLEM BEFORE. THE CAR HAS ABOUT 80,000 MILES ON IT.
NHTSA ODI #10787047
89,000 miles · Oct 21, 2015
Vehicle Speed Control
I WAS CRUISING ALONG A MAJOR URBAN HIGHWAY @ 50MPH WHEN I SUDDENLY LOST THE ABILITY TO ACCELERATE. CAR LOST SPEED AND WENT TO 45 THEN DOWN TO 40 AND I WAS UNABLE TO ACCELERATE. LUCKILY TRAFFIC WAS LIGHT AND I WAS ABLE TO CROSS THE TWO LANES OVER TO THE RIGHT AND EXIT THE MAIN ROAD AND LIMPED ALONG TO A STOP IN A SAFE AREA. DEALE…
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I WAS CRUISING ALONG A MAJOR URBAN HIGHWAY @ 50MPH WHEN I SUDDENLY LOST THE ABILITY TO ACCELERATE. CAR LOST SPEED AND WENT TO 45 THEN DOWN TO 40 AND I WAS UNABLE TO ACCELERATE. LUCKILY TRAFFIC WAS LIGHT AND I WAS ABLE TO CROSS THE TWO LANES OVER TO THE RIGHT AND EXIT THE MAIN ROAD AND LIMPED ALONG TO A STOP IN A SAFE AREA. DEALERSHIP HAD TO REPLACE THE THROTTLE BODY AND MOTOR. WAS NOT COVERED BY FORD'S CSP 13N03 WHICH HAD BEEN ISSUED FOR A SIMILAR PROBLEM. WAS TOLD THE PROGRAM DID NOT APPLY TO THE HYBRID MODEL, AND YET IT WAS THE SAME PROBLEM DESCRIBED IN THE NHTSA ACTION NUMBER PE 13003!
NHTSA ODI #10784450
70,000 miles · Oct 14, 2015
Structure
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
NHTSA ODI #10782230
38,500 miles · Oct 6, 2015
Engine
ON 2 DIFFERENT DAYS, DRIVING ON FREEWAY, MY 2010 FORD FUSION HYBRID, DID NOT RESPOND TO ACCELERATOR DEMAND, I.E. FAILED TO SPEED UP AS COMMANDED, THE WRENCH LIGHT ILLUMINATED BUT NO CHECK ENGINE LIGHT. THIS PROBLEM SEEMS INTERMITTENT, DEALER CANNOT PIN POINT THE PROBLEM BUT REPLACING THE ELECTRONIC THROTTLE BODY(ETB) FIXED THE P…
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ON 2 DIFFERENT DAYS, DRIVING ON FREEWAY, MY 2010 FORD FUSION HYBRID, DID NOT RESPOND TO ACCELERATOR DEMAND, I.E. FAILED TO SPEED UP AS COMMANDED, THE WRENCH LIGHT ILLUMINATED BUT NO CHECK ENGINE LIGHT. THIS PROBLEM SEEMS INTERMITTENT, DEALER CANNOT PIN POINT THE PROBLEM BUT REPLACING THE ELECTRONIC THROTTLE BODY(ETB) FIXED THE PROBLEM. I FOUND MANY SIMILAR COMPLAINTS ONLINE. NHTSA ACTION NO. PE 13003 WHICH IDENTIFIES CARS MODELS AFFECTED INCLUDES MY CAR, AND THE ACTION RESULTED IN A CUSTOMER SATISFACTION PROGRAM THAT EXTENDED THE WARRANTY ON THE ETB. HOWEVER, FORD CLAIMS MY VIN IS NOT INCLUDED. I HAVE FOUND OTHERS IN THE SAME SITUATION AND HAVE FILED COMPLAINTS, E.G.NHTSA ID NUMBER 10778131, AND CARCOMPLAINTS.COM.
NHTSA ODI #10779977
70,000 miles · Sep 30, 2015
Power Train
WHEN DRIVING A LONG PERIOD OF TIME 100-300 MILES THE WRENCH WILL APPEAR. AFTER PULLING OFF AND LETTING IT SIT FOR ABOUT 30 MINUTES IT GOES OFF, ONLY TO COME BACK ON AFTER DRIVING ANOTHER 100-300 MILES.
NHTSA ODI #10778615
135,000 miles · Sep 30, 2015
Steering
WHILE MY DAUGHTER WAS DRIVING MY CAR THE POWER STEERING FAILED UNEXPECTEDLY AND SHE WAS LUCKY SHE WAS NEAR OUR HOME. I BROUGHT THE CAR TO THE DEALERSHIP AND THEY SAID THE PART WILL COST $1500 AND IT IS ON BACKORDER FOR OVER TWO WEEKS! I BOUGHT THIS CAR USED AND FOUND OUT THE SAME PART WAS REPLACED AT 65,000 MILES. I WAS TOLD …
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WHILE MY DAUGHTER WAS DRIVING MY CAR THE POWER STEERING FAILED UNEXPECTEDLY AND SHE WAS LUCKY SHE WAS NEAR OUR HOME. I BROUGHT THE CAR TO THE DEALERSHIP AND THEY SAID THE PART WILL COST $1500 AND IT IS ON BACKORDER FOR OVER TWO WEEKS! I BOUGHT THIS CAR USED AND FOUND OUT THE SAME PART WAS REPLACED AT 65,000 MILES. I WAS TOLD BY THE DEALERSHIP THAT IT'S COMMON TO HAVE TO REPLACE THAT PART EVERY 65,000 MILES! I HAVE HAD MANY CARS AND I HAVE NEVER ONCE HAD TO REPLACE A STEERING GEAR, NEVER MIND TWICE. I THINK FORD HAS FAULTY PARTS AND SHOULD TAKE ACCOUNTABILITY FOR IT!! RIGHT NOW I AM OUT OF A CAR FOR OVER TWO WEEKS AND THE DEALERSHIP THEY CAN NOT GIVE ME A LOANER EVEN THOUGH IT'S FORD WHO DOESN'T HAVE THE PART. I WILL NEVER BUY A FORD AGAIN AFTER THIS. THE CARS ARE UNSAFE AMD NO ONE IS DOING A THING ABOUT IT! [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).' *JB
NHTSA ODI #10778613
105,000 miles · Sep 28, 2015
Engine
I HAVE HAD MULTIPLE INCIDENTS WITH MY 2010 FORD FUSION HYBRID WHERE I HAVE BEEN DRIVING AND THE ENGINE WILL SUDDENLY LOSE POWER AND THE THROTTLE BECOMES UNRESPONSIVE. SOME OF THESE INCIDENTS OCCURRED DURING FREEWAY DRIVING. WHEN THIS HAPPENED, AN ORANGE WRENCH WOULD APPEAR ON MY DASH DISPLAY, SOMETIMES ACCOMPANIED BY THE CHECK E…
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I HAVE HAD MULTIPLE INCIDENTS WITH MY 2010 FORD FUSION HYBRID WHERE I HAVE BEEN DRIVING AND THE ENGINE WILL SUDDENLY LOSE POWER AND THE THROTTLE BECOMES UNRESPONSIVE. SOME OF THESE INCIDENTS OCCURRED DURING FREEWAY DRIVING. WHEN THIS HAPPENED, AN ORANGE WRENCH WOULD APPEAR ON MY DASH DISPLAY, SOMETIMES ACCOMPANIED BY THE CHECK ENGINE LIGHT. AFTER DOING SOME RESEARCH, I FOUND THAT THIS IS A KNOWN ELECTRONIC THROTTLE BODY ISSUE. PER NHTSA ACTION NUMBER : PE13003, FORD HAD ISSUED AN EXTENDED WARRANTY PROGRAM TO COVER REPLACEMENT OF THIS DEFECTIVE PART, BUT THEY ELECTED TO EXCLUDE THE FUSION HYBRID. UPON CONTACTING FORD CUSTOMER SERVICE AND SPEAKING WITH A SUPERVISOR. I WAS ADVISED THAT FORD WAS EXCLUDING THE HYBRID MODEL BECAUSE ITS 2.5L ENGINE IS DIFFERENT THAN THE 2.5L ENGINES IN THE NON-HYBRID MODELS. WHILE THERE MAY BE DIFFERENCES IN THE ENGINE, THIS IS STILL THE SAME DEFECTIVE PART NUMBER THAT IS IN ALL OF THE OTHER FORD VEHICLES THAT RECEIVED THE EXTENDED WARRANTY, AND ACCORDING TO THE SERVICE MANAGER AT THE DEALERSHIP WHERE I HAD THE CAR SERVICED, THE CAR INCORRECTLY RETURNED THE SAME ERROR CODE (P2112, "THROTTLE BODY STUCK CLOSED") THAT THE COVERED VEHICLES RETURNED. THE SERVICE MANAGER ADVISED THAT IT MAKES NO SENSE THAT MY VEHICLE WOULD BE EXCLUDED AND ADVISED THAT I CONTACT FORD CUSTOMER SERVICE. I WAS ADVISED BY CUSTOMER SERVICE THAT EVEN THOUGH THE PART IS DEFECTIVE WHEN INSTALLED ON SOME VEHICLES, IT MAY NOT BE DEFECTIVE WHEN INSTALLED ON OTHERS. THAT SAID, THE PART DISPLAYED THE SAME PATTERN OF FAILURE, THE SAME SYMPTOMS AND THE SAME ERROR CODES AS THE PART COVERED UNDER THE EXTENDED WARRANTY. IT'S THE SAME DEFECTIVE PART. IT MAKES NO SENSE THAT 1.6 MILLION THROTTLE BODIES MAY BE FAULTY ON NON-HYBRID VEHICLES, BUT THE SAME PART HAPPENS TO BE OKAY ON ALL 60,000 FUSION HYBRIDS. I WAS FORCED TO MAKE THE REPAIR OUT OF POCKET.
NHTSA ODI #10778131
53,608 miles · Sep 12, 2015
StructureUnknown Or Other
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.
NHTSA ODI #10763329
34,400 miles · Sep 8, 2015
EngineVehicle Speed Control
WHEN DRIVING ON THE HIGHWAY AT APPROXIMATELY 70 MPH, THE WRENCH INDICATOR LIGHT ("LIMP HOME" MODE) SUDDENLY STARTED FLASHING, AND THE GAS PEDAL ABRUPTLY BECAME UNRESPONSIVETHE VEHICLE WOULD NO LONGER ACCELERATE AND COULD ONLY COAST. THE ABRUPTLY DECELERATING VEHICLE WAS MANEUVERED ACROSS MULTIPLE LANES OF TRAFFIC TO THE SHOULDER…
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WHEN DRIVING ON THE HIGHWAY AT APPROXIMATELY 70 MPH, THE WRENCH INDICATOR LIGHT ("LIMP HOME" MODE) SUDDENLY STARTED FLASHING, AND THE GAS PEDAL ABRUPTLY BECAME UNRESPONSIVETHE VEHICLE WOULD NO LONGER ACCELERATE AND COULD ONLY COAST. THE ABRUPTLY DECELERATING VEHICLE WAS MANEUVERED ACROSS MULTIPLE LANES OF TRAFFIC TO THE SHOULDER AND TURNED OFF. UPON RESTARTING THE VEHICLE AFTER A MINUTE, IT WAS ABLE TO RESUME NORMAL OPERATION FOR ABOUT 15 MINUTES, WHEN THE PROBLEM REOCCURRED, AND THE SAME STEPS WERE TAKEN. IT OCCURRED AGAIN 90 MINUTES LATER. SYMPTOMS CORRESPOND TO OTHER ACCOUNTS OF ELECTRONIC THROTTLE BODY ISSUES, BUT FORD SAYS THAT THE VEHICLE IS NOT COVERED UNDER ANY RECALLS, EXTENDED WARRANTIES, OR CUSTOMER SAFETY PROGRAMS.
NHTSA ODI #10762159
98,000 miles · Sep 5, 2015
Service BrakesCrash
OUR FORD FUSION HYBRID EXPERIENCED A TOTAL BRAKE FAILURE AS I WAS DRIVING OUT OF OUR CANYON. I HAD JUST STOPPED TO LET A COUPLE OF CARS PASS ON THE NARROW ROAD AND AS I PROCEEDED INTO A 90 DEGREE DOWNHILL TURN, THE BRAKES FAILED, CAUSING A CRASH. THERE WAS NO BRAKING WHATSOEVER. I HAD ONLY 2 OR 3 SECONDS BEFORE THE TURN AND MAN…
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OUR FORD FUSION HYBRID EXPERIENCED A TOTAL BRAKE FAILURE AS I WAS DRIVING OUT OF OUR CANYON. I HAD JUST STOPPED TO LET A COUPLE OF CARS PASS ON THE NARROW ROAD AND AS I PROCEEDED INTO A 90 DEGREE DOWNHILL TURN, THE BRAKES FAILED, CAUSING A CRASH. THERE WAS NO BRAKING WHATSOEVER. I HAD ONLY 2 OR 3 SECONDS BEFORE THE TURN AND MANAGED TO AVOID GOING OFF OF A CLIFF ONLY NARROWLY, BY RUNNING UP A EARTHEN BANK AND OVER A LARGE BOULDER, WHICH STOPPED THE CAR. THE CONSUMER REPORTS TEST DRIVER HAD THE SAME EXPERIENCE WHEN TEST DRIVING THE CAR IN 2010.
NHTSA ODI #10761799
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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