2018 Ford Fusion

Engine failure as described in TSB 22-2229, confirmed by local Ford dealer (Bill Brown Ford in Livonia, MI). This issue is not a normal wear & tear issue, it is a combination of Design & Manufacturing flaw (known by Ford) however Ford Warranty will not provide me with any financial assistance for the repair. An engine should never have the wall between the piston cavity and cooling cavity break down ever. This issue should be under a recall. This failure could easily have taken place on the interstate at night leading to immediate side of the road situation and very nearly did since we were to take a trip several states away the next day.

The contact owns a 2018 Ford Fusion. The contact stated while driving approximately 55 MPH, she observed that a cloud of white smoke was coming from the exhaust pipe. The contact stated that the vehicle lost motive power and stalled; however, the engine started to misfire, and the vehicle was shaking abnormally. The contact stated that a message that the engine was overheating was displayed. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that coolant had intruded into cylinders #1, #2, and #3. The dealer determined that the short block needed to be replaced. The vehicle was repaired; however, the failure recurred. The manufacturer had been informed of the failure. The contact was informed by the manufacturer that the failure was related to Customer Satisfaction Program: 21N12 - Coolant Intrusion (Engine and Engine Cooling) and that the repair had been a one-time free repair. The failure mileage was approximately 137,000.

The contact owns a 2018 Ford Fusion. The contact stated while driving 60 MPH, the powertrain malfunction warning light illuminated. The contact stated that the vehicle started overheating. The contact pulled over and turned off the vehicle. The vehicle was towed back to the residence. The vehicle was then towed to the dealer and the dealer stated that coolant was leaking into the engine and that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was contacted but provide no assistance. The contact was referred to the NHTSA Hotline for assistance. The failure mileage was 151,981.

The contact owns a 2018 Ford Fusion. The contact stated that while driving at an undisclosed speed, the check engine warning light remained illuminated. The vehicle was towed to the local dealer who diagnosed the vehicle and determined that engine coolant had leaked into the cylinder #3, causing severe damage to the engine. The contact was informed that the engine needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure and informed the contact that the VIN was no longer eligible for the Extended Warranty Coverage. The failure mileage was 109,000.

The contact owns a 2018 Ford Fusion. The contact stated that the vehicle failed to start soon after refueling. Additionally, while stationary and while driving at various speeds, the vehicle would hesitate or stall upon depression of accelerator pedal. The contact also stated that the powertrain warning light would intermittently appear on the instrument panel. The manufacturer was notified of the failure and the contact was informed that there were no open recalls on the VIN. The vehicle was not repaired. The failure mileage was unknown.

The contact owns a 2018 Ford Fusion. The contact stated that while operating the vehicle, there was a sound of liquid present inside the dashboard. The vehicle was taken to the local dealer who diagnosed that engine coolant was present inside the engine cylinders and the engine short block needed to be placed. The engine short block was replaced but later the vehicle began to drive sluggishly and would not properly accelerate. The vehicle was taken to a second dealer who diagnosed that the engine was faulty and needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure. The failure mileage was 110,000.

The contact owns a 2018 Ford Fusion. The contact stated that while starting the vehicle and shifting into reverse(R), she was unable to shift between gears. There was no warning light illuminated. The vehicle was towed to the residence. The vehicle was then towed to an independent mechanic, where it was diagnosed that the under hood shifter cable bushing needed to be replaced. The vehicle was repaired. Additionally, the contact stated that the vehicle was taken back to the mechanic for routine oil change service; however, while driving at an undisclosed speed, the check engine warning light was illuminated. The vehicle was taken back to the independent mechanic, where it was diagnosed that the canister purge valve (CPV) needed to be replaced. The contact stated that the part was replaced; however, the vehicle stalled after being refueled. The vehicle was taken back to the mechanic, where the failure could not be duplicated. The vehicle was not repaired. The dealer was not contacted. The manufacturer was made aware of the failures and confirmed that the VIN was not included in NHTSA Campaign Numbers: 18V735000 (Fuel System, Gasoline) and 22V413000 (Power Train). The manufacturer advised the contact to file a complaint with the NHTSA hotline. The approximate failure mileage was unknown.