Air Bags. Review the 319 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 150 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Structure. Review the 74 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

38 crash reports4 fire reports23 injury reports

Electrical System complaints

71 reports

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116,000 miles · Aug 31, 2011

Electrical System

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I TOO HAVE A 2006 FORD FUSION SE WITH A SMARTBOX MALFUNCTION. MY DRIVER'S SIDE DIRECTIONAL SIGNAL DOESN'T WORK. MY MECHANIC SAID HE CHECKED ALL THE WIRES LENDING TO THE BOX AND THEY ARE FINE, IT'S THE BOX. IT WILL COST AROUND $600 TO REPLACE. FORD NO LONGER MAKES THIS PART, SO HE HAS TO SEARCH JUNKYARDS FOR IT. HE CAN'T REROUTE THE WIRES BECAUSE THE DIRECTIONAL SIGNAL IN THE BACK IS LOCATED IN THE PLACE WHERE HE WOULD REROUTE IT. I NOW HAVE A VEHICLE THAT WILL NOT PASS INSPECTION, THAT I CAN'T DRIVE "SAFELY" AND IF THE PART IS FOUND I WILL HAVE TO TAKE OUT A LOAN JUST TO PAY TO GET FIXED. WHY! *TR

NHTSA ODI #10422708

820,000 miles · Aug 2, 2011

Electrical SystemFire

I OWNED A 2006 FORD FUSION, THIS CAR CAUGHT ON FIRE AT 4AM. IT WAS RULED AS AN ELECTRICAL FIRE. THERE WERE NO PROBLEMS LEADING UP TO THIS FIRE. *KB

NHTSA ODI #10416614

85,000 miles · Jul 26, 2011

Electrical System

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SINCE I BOUGHT THE CAR IN SPRING OF 06, BULBS NEED TO BE REPLACED QUITE FREQUENTLY. WHEN I CHANGE THEM, THE OLD BULB LOOKS BLACK AND BURNT. A FEW DAYS AGO, I WAS DRIVING AND MY FRONT, RIGHT DIRECTIONAL STOPPED WORKING. I REPLACED THE BULB, THINKING THAT WAS THE ISSUE AGAIN, BUT IT WASN'T. I TOOK IT TO THE DEALERSHIP AND THEY SAID THE SMART JUNCTION BOX NEEDED TO BE REPLACED BECAUSE IT SHORTED OUT INTERNALLY. ESTIMATE IS $600 AFTER I HAD TO PAY $100 JUST TO FIND THE PROBLEM. THAT SEEMS LIKE AN EXPENSIVE FIX FOR ONE DIRECTIONAL. I CAN'T AFFORD THAT RIGHT NOW, SO I CAN'T FIX IT. SEEMS RIDICULOUS. CAR HAS 85,000 MILES ON IT. *TR

NHTSA ODI #10415232

98,000 miles · Jul 8, 2011

Electrical SystemExterior Lighting

FRONT DRIVER'S SIDE INDICATOR/HAZARD LIGHT NOT WORKING. LEFT REAR DRIVER SIDE WORKS. CONSENSUS IS EITHER A SMART JUNCTION BOX OR HEADLIGHT HARNESS. COST OF REPAIRS AROUND $600 NOT INCLUDING LABOR. VERY COSTLY FOR ONE TURN SIGNAL. BIG MISTAKE ON FORD'S PART.

NHTSA ODI #10412492

92,000 miles · Mar 12, 2011

Electrical SystemExterior Lighting

IN 2006 I BOUGHT A 2006 FORD FUSION. I HAVE HAD PROBLEMS SINCE I GOT IT BLOWING BULBS IN THE TURN SIGNALS. I NOW FIND OUT THAT IT IS MY SMART JUNCTION BOX CAUSING THIS AND FORD MOTOR WILL DO NOTHING ABOUT IT. PART OF THE SMART JUNCTION BOX IS MELTED TOGETHER. THIS IS FORD'S FAULTY DESIGN AND THEIR FAULT. *TR

NHTSA ODI #10389946

54,000 miles · Dec 15, 2010

Electrical System

TL*THE CONTACT OWNS A 2006 FORD FUSION. THE CONTACT STATED THAT THE KEYS WOULD NOT RELEASE FROM THE IGNITION UNLESS THE BUTTON ON THE GEAR SHIFT WAS PUSHED IN TO RELEASE THE KEY. THE CONTACT HAD TO REMOVE A PIECE OF PLASTIC IN ORDER TO REMOVE THE KEY FROM THE IGNITION SWITCH. THE CONTACT NOTICED NUMEROUS COMPLAINTS REGARDING THE…

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NHTSA ODI #10370839

96,590 miles · Oct 20, 2010

Electrical System

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WHEN DRIVING ON THE INTERSTATE UNDER CRUISE CONTROL, THE ENGINE SUDDENLY DROPPED TO IDLE AND WOULD NOT RESPOND TO THE THROTTLE. FORTUNATELY I WAS ABLE TO COAST TO THE SIDE OF THE ROAD WITHOUT BEING HIT FROM BEHIND. THE CAR SHOWED TWO WARNING LIGHTS: TRACTION CONTROL AND THROTTLE CONTROL. THE CAR WOULD STILL NOT RESPOND TO THE THROTTLE. AFTER TURNING OFF THE CAR AND RESTARTING IT, THE LIGHTS WENT OUT AND THE CAR WAS DRIVABLE AGAIN. I TOOK THE CAR TO THE DEALER, WHO CLEANED THE THROTTLE BODY, FLUSHED THE FUEL INJECTORS AND REPROGRAMMED THE PCM. WHATEVER ACTUALLY HAPPENED, THE FAIL SAFE CONDITION SHOULD NOT BE TO SHUT THE ENGINE DOWN TO IDLE WITHOUT THE ABILITY TO CONTROL THE ENGINE SPEED. IT WAS JUST FORTUNATE THAT THE CAR WAS NOT HIT FROM BEHIND. *TR

NHTSA ODI #10361452

55,550 miles · Jul 26, 2010

Electrical SystemPower Train

I AM UNABLE TO REMOVE MY KEY FROM MY IGNITION UNLESS I REMOVE A PIECE OF THE SHIFTER ON MY TRANSMISSION. *TR

NHTSA ODI #10345294

92,000 miles · Jul 7, 2010

Electrical System

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TL*THE CONTACT OWNS A 2006 FORD FUSION. THE CONTACT STATED THAT THE KEY WAS STUCK IN THE IGNITION. HE HAD TO USE THE SPARE KEY TO LOCK AND UNLOCK THE DOORS. SINCE THE KEY WAS STUCK IN THE IGNITION HE LEFT IT THERE. EVENTUALLY THE CONTACT WAS ABLE TO REMOVE THE KEY FROM THE IGNITION; HOWEVER, THE FAILURE CONTINUED TO OCCUR. THE DEALER WAS CONTACTED AND STATED THAT THEY COULD REPLACE THE KEY FOR $180.00 AT THE OWNERS EXPENSE OR REPLACE THE ENTIRE SHIFT ASSEMBLY FOR APPROXIMATELY $500.00. THE DRIVERS SIDE DOOR HANDLE WAS ALSO DEFECTIVE. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 92,000.

NHTSA ODI #10341814

60,000 miles · Jun 29, 2010

Electrical SystemExterior Lighting

RIGHT FRONT SIDE TURN SIGNAL LIGHT FAILED INSPECTION REPLACED BULB AND ELECTRICAL HARNESS, STILL NO POWER. DIAGNOSED AS DEFECTIVE SMART BOX FORD ESTIMATES IT AT $800 TO REPLACE. *TR 4 YEAR OLD FORD FUSION (SUMMER 2006)

NHTSA ODI #10340569

Official recalls

21V158000 · Air Bags:frontal:driver Side:inflator Module

Mar 10, 2021

Ford Motor Company (Ford) is recalling certain 2007-2011 Ranger, 2006-2012 Fusion, Lincoln Zephyr, Lincoln MKZ, 2006-2011 Mercury Milan, 2007-2010 Ford Edge, and Lincoln MKX vehicles. The driver's side air bag inflator may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.

Consequence & remedy

Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.

Remedy: Ford will notify owners, and dealers will replace the driver-side airbag inflator or module with an alternate one, free of charge. Owner notification letters were mailed on April 9, 2021 for the passenger side, and November 14, 2022 for the driver side. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S12.

19V904000 · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Dec 18, 2019

Ford Motor Company (Ford) is recalling certain 2006-2010 Ford Fusion, Mercury Milan, Lincoln Zephyr and MKZ vehicles. The valves within the ABS Hydraulic Control Units (HCU) may react with brake fluids containing specific corrosion preventative additives. This reaction may cause the valves to not close properly.

Consequence & remedy

Consequence: If the valves do not properly close, additional brake pedal travel may be required to stop the vehicle, increasing the risk of a crash.

Remedy: Ford will notify owners, and dealers will flush the brake system with DOT 4 fluid and install a new brake fluid reservoir cap. In addition, the HCU will be tested to detect a possible stuck valve condition, replacing the HCU as necessary. All services will be performed free of charge. The recall began April 1, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S54.

17V024000 · Air Bags:frontal:passenger Side:inflator Module

Jan 10, 2017

Ford Motor Company (Ford) is recalling certain 2012 Ford Fusion and Mustang and Lincoln Zephyr and MKZ vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Ford is recalling certain 2009 Ford Ranger, Edge, Fusion and Mustang, Lincoln MKX, MKZ and Zephyr and Mercury Milan vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia and West Virginia, or "Zone B." Additionally, unless included in "Zone A" or "Zone B" above, Ford is recalling certain 2007-2008 Ford Ranger, Edge and Lincoln MKX, 2006-2008 Ford Fusion, Mercury Milan, Lincoln Zephyr and MKZ, 2005-2008 Ford Mustang and 2005-2006 Ford GT vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin and Wyoming. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the passenger frontal air bag, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.

Consequence & remedy

Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.

Remedy: Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Interim letters informing owners of the recall and that parts are not yet available began mailing March 1, 2017. Owners will receive a second notice when remedy parts become available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S01.

16V384000 · Air Bags:frontal:passenger Side:inflator Module

May 31, 2016

Ford Motor Company (Ford) is recalling certain model year 2007-2011 Ford Ranger vehicles, 2006-2011 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2007-2010 Ford Edge, Lincoln MKX vehicles, 2005-2006 Ford GT vehicles, and 2005-2011 Ford Mustang vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Ford is recalling certain model year 2007-2008 Ford Ranger, Edge and Lincoln MKX vehicles, 2006-2008 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2005-2006 Ford GT vehicles and 2005-2008 Ford Mustang vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia, or "Zone B." Any vehicle not included in "Zone A", or "Zone B" is not included in the safety recall. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.

Consequence & remedy

Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.

Remedy: Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Ford mailed interim letters informing owners that parts are not yet available on July 15, 2016. Owners will receive a second notice when remedy parts become available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S01.

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

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

Vehicle Speed Control