2020 Ford Fusion

The contact owns a 2020 Ford Fusion. The contact stated that after starting the vehicle there was an abnormally loud knocking sound coming from the engine compartment. The vehicle was taken to the local dealer who diagnosed that the flex plate was cracked and needed to be replaced along with the torque converter, the transmission fluid pump, and seals. The vehicle was repaired. The manufacturer was notified of the failure and informed the contact that the vehicle was no longer eligible for a Customer Satisfaction Campaign related to the failure. The failure mileage was 122,000.

The contact owns a 2020 Ford Fusion. The contact stated that while reversing from the residence, the vehicle suddenly stopped and shifted into park. The contact shifted to reverse, but the gear shifter independently shifted back to park. The contact stated that the vehicle failed to shift to the intended gear. The transmission shifter and the see the owner’s manual messages were displayed. There was a WRENCH symbol displayed. The contact stated that the failure was related to NHTSA Campaign Number: 22V413000 (Power Train); however, the VIN was not included. The contact called the local dealer, who confirmed that there were no recalls on the VIN. The vehicle was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline, but no additional assistance was provided. The failure mileage was approximately 79,127.

Component or system that failed: Flex plate, engine electrical system, and alternator (possible related failures). The issue has been diagnosed by a licensed mechanic and is available for inspection upon request. Incident Description: On April 15, 2025, while driving my 2020 Ford Fusion SE 1.5L Turbo, the vehicle suddenly experienced a total power failure. The check engine light began flashing, and the battery light blinked rapidly. Within seconds, the engine shut down completely while I was mid-drive in traffic, leaving me stuck and unable to move for over 20 seconds. This was a terrifying and dangerous situation that nearly put my life at risk. I was eventually able to restart the vehicle, but it began shaking and rumbling violently — worse than ever before. This issue was never present before my car was involved in two separate collisions, where both other drivers were found 100% at fault. The vehicle was repaired at Fix Auto Santee (a USAA-assigned body shop), but they failed to inspect internal components. A licensed mechanic at J&L Auto Care later confirmed a broken flex plate and advised it was unsafe to drive. This problem has not been addressed or fixed by the responsible insurers (USAA and AAA) or the body shop. It has progressively worsened and now created a life-threatening situation. Warning lamps or symptoms before failure: A rattling and vibrating noise began immediately after I picked up the car from the body shop in March 2025. No lights were initially present. The electrical and engine lights only appeared on April 15 when the engine shut down mid-drive. Inspected by: •Independent service center (J&L Auto Care, diagnosed flex plate failure) •USAA and AAA were informed but refused to cover or further inspect the damage •Fix Auto Santee heard the issue but refused to inspect, citing body-only service Problem available for inspection: Yes — vehicle is currently undrivable and available for full inspection.

The contact owns a 2020 Ford Fusion. The contact stated while driving 70 MPH, the vehicle started pulling and veering to the right, while driving on uneven pavement. The power steering assist warning light illuminated while driving over 35 MPH. On another occasion, the steering wheel failed to respond, and the vehicle spun out and the vehicle came to a stop in the right lane. The vehicle was taken to a tire shop where it was diagnosed with rack and pinion failure, and the vehicle was aligned. The vehicle was repaired; however, the failure persisted. The contact then took the vehicle to an independent mechanic who diagnosed the vehicle with a steering assist sensor fault. The brakes were calibrated; however, when the contact depressed the brake pedal, the brakes failed to respond, and the contact stopped depressing on the accelerator pedal to have the vehicle slow down to stop the vehicle. The dealer was not made aware of the failure. The vehicle was not repaired for the most recent failure. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 87,361.

The contact owns a 2020 Ford Fusion. The contact stated that while driving approximately 35 MPH, the message "Engine Coolant Over-Temperature" was displayed, and the temperature gauge warning light illuminated. The contact pulled over to the side of the road and turned off the vehicle. The vehicle was restarted after 20 minutes. The vehicle was taken to the residence. The vehicle was towed to a dealer, where it was diagnosed and determined that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 132,000.

I have had 2 transmissions within the last year, making this the third Transmission on my vehicle. I had to have another common issue with the car replaced, which is a purge valve. My ABS light goes off often causing difficulty to steer the car and warning lights are activated showing that the safety features are not available. Lastly, there is a crack in the engine block caused by coolant in the spark plug due to overheating. This engine issue is one with the engines that Ford is aware of but I do NOT see a recall. The engine is blown due to this design and the warranties do NOT cover it. Case number [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2020 Ford Fusion. The contact stated that after starting the vehicle, while the vehicle was idling, there was an abnormal knocking sound coming from the engine. There was no warning light illuminated. The vehicle was taken to two independent mechanics, and unknown repairs were performed on the vehicle; however, the failure persisted. The contact took the vehicle to a dealer, where a diagnostic test was performed. The diagnostic test determined that the flex plate was cracked and needed to be replaced. The manufacturer was notified of the failure but offered no assistance. The contact was referred to the NHTSA Hotline to report the failure. The vehicle was not repaired. The failure mileage was approximately 117,000.

The manufacturer is using the wrong material for the parts on my car. Currently, the right-side lower control bushing is bulging out because a steel bushing was used instead of the aluminum one specified on the website. This issue is causing my car to pull to the right, making steering difficult. I've also experienced the same problem on the left side in the past. I request a recall to fix this and ensure the safety of all drivers on the road.

The contact owns a 2020 Ford Fusion. The contact stated that while driving at approximately 40 MPH, there was an abnormal rattling sound coming from the engine compartment. The contact stated that the sound was more evident while the vehicle was idling. The vehicle was taken to an independent mechanic and was diagnosed with a fractured flex plate. The contact was informed that the flex plate needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 63,000.