2007 Ford Fusion
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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These records cover every 2007 Ford Fusion. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
5 recalls name the 2007 Ford Fusion. Newest first.
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…
Risk and remedy
Risk
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.
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.
Risk and remedy
Risk
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.
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…
Risk and remedy
Risk
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.
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…
Risk and remedy
Risk
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.
Ford Motor Company (Ford) is recalling certain all weather driver side accessory floor mats sold for use in model year 2006-2011 Ford Fusion and Mercury Milan, 2006 Lincoln Zephyr, and 2007-2011 Lincoln MKZ vehicles manufactured November 9, 2007, through October 31, 2010. The affected floor mats may move and possibly interfere with the accelerator pedal.
Risk and remedy
Risk
The floor mat could shift such that it could interfere with the accelerator pedal, preventing its return to an idle position, which could result in unintended vehicle speeds, increasing the risk of a crash.
Remedy
Ford will notify owners, and dealers will install new replacement mats, free of charge. The recall began in July 2014. Owners may contact Ford's customer service at 1-800-392-3673. Ford's number for this recall is 14S07. NOTE: Vehicles built after October 31, 2010, while potentially equipped with the same floor mats, are equipped with a Brake Over Accelerator (BOA) feature that prevents simultaneous accelerator and brake application, allowing the vehicle to be safely stopped by pressing firmly and steadily on the brake pedal.
Owner complaints
1,064 complaints58 involved a crash5 involved a fire56 injuries1 deaths
What owners report most
Latest complaints
- Seats
Drivers seat moved back while driving and now won't move forward I am only 4ft 8 inch tall and driving my car is very difficult I have seen a lot of other people complaining of the same thing and something needs to be done
- Unknown or other
i need to check engine make/brand
- Seats · Unknown or other
Took car to dealer because the dash light came on what looked like airbag needed replacement.? I had had that done so they checked and told me it was a weight bar in passenger seat that was lighting up. Does that not protect person from collision and trigger airbag if u have accident.?? Would that…
Took car to dealer because the dash light came on what looked like airbag needed replacement.? I had had that done so they checked and told me it was a weight bar in passenger seat that was lighting up. Does that not protect person from collision and trigger airbag if u have accident.?? Would that not be a necessary fix even if cars out of warranty? They could not answer that and said I would have to pay over 750.00 to correct.. I walked out. What’s the real truth here. This car is a 2007!! Who would pay that amount..
- Electrical system · Seats
Driver's side front seat will stop moving forward and back it has been tested said all was good it moved back on it own while driving now I am 4 ft 8 inches tall not good I was stopped at a red light
- Air bags
The contact owns a 2007 Ford Fusion. The contact stated that while operating the vehicle, the air bag warning light had remained illuminated. The cause of the failure was not yet determined. The local dealer and manufacturer were notified of the failure, but no assistance was offered. The failure mileage was approximately 43,000.
- Air bags · Power train
The contact owns a 2007 Ford Fusion. The contact received notification of NHTSA Campaign Number: 19V001000 (Air Bags) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact…
The contact owns a 2007 Ford Fusion. The contact received notification of NHTSA Campaign Number: 19V001000 (Air Bags) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that while driving at an undisclosed speed, the vehicle hesitated to accelerate. The air bag and check engine warning lights were illuminated. The vehicle later failed to be started. The vehicle was towed to the residence by AAA, who attempted to jumpstart the vehicle, but the vehicle failed to start. AAA related the failure to the transmission; however, the vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure but confirmed that the air bag parts were on backorder. The failure mileage was unknown. Parts distribution disconnect.
- Seats
My airbag light came on 2 days after driver side air bag was replaced. Dealer wanted $129.50 to tell me the reason. After checking I was told it IS somewhere in the wiring in the passenger seat and it will cost me $500. To remove the seat and the seat covers and an estimated $500 to fix the wiring…
My airbag light came on 2 days after driver side air bag was replaced. Dealer wanted $129.50 to tell me the reason. After checking I was told it IS somewhere in the wiring in the passenger seat and it will cost me $500. To remove the seat and the seat covers and an estimated $500 to fix the wiring problem. I am [xxx] and that IS a lot of money for me to pay. Why IS a problem like that my problem and not ford motor??? I have been told by several people that ford had a lot of problems with my model 2007 ford fusion. Again why IS a safety problem mine and not ford motor??.[xxx] information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(B)(6)
- Engine · Suspension › Multiple axle
The contact owns a 2007 Ford Fusion. The contact stated that while driving at 30 MPH, there was an abnormal metal sound detected. The vehicle began to shake abnormally and stalled. There were no warning lights illuminated. The vehicle was towed to an independent mechanic, who informed her the…
The contact owns a 2007 Ford Fusion. The contact stated that while driving at 30 MPH, there was an abnormal metal sound detected. The vehicle began to shake abnormally and stalled. There were no warning lights illuminated. The vehicle was towed to an independent mechanic, who informed her the failure was due to the axle. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 140,000.
- Air bags
The passenger airbag was replaced, and is now trying to pop out of the cover. The upper left corner is bulging outward.
- Service brakes, air › Antilock › Control unit/module
ABS and WRENCH icon are flashing on dashboard. Car making a terrible noise from underneath . I try to drive the car but it loses power and goes into LIMP mode. I have read many problems with the ABS control module valves sticking open due to the wrong type of brake fluid put in by manufacturer.…
ABS and WRENCH icon are flashing on dashboard. Car making a terrible noise from underneath . I try to drive the car but it loses power and goes into LIMP mode. I have read many problems with the ABS control module valves sticking open due to the wrong type of brake fluid put in by manufacturer. My car is a 2007 ford fusion sel AWD with only 89,000 miles. I need a recall service appointment as quickly as possible because this is the only vehicle I own. The car is just sitting in my driveway. HELP!!!!!!!!!
- Air bags
The contact owned a 2007 Ford Fusion. The contact stated while driving 40 MPH, and merging into the slow lane, he crashed into a vehicle that stopped abruptly. Additionally, the vehicle was rear-ended by another vehicle. The driver air bag exploded. The contact was able to exit the vehicle without…
The contact owned a 2007 Ford Fusion. The contact stated while driving 40 MPH, and merging into the slow lane, he crashed into a vehicle that stopped abruptly. Additionally, the vehicle was rear-ended by another vehicle. The driver air bag exploded. The contact was able to exit the vehicle without assistance. The contact was transported to the hospital with the assistance of Uber. The contact was informed that he had sustained a broken sternum and bruised ribs. A police report was filed. The vehicle was towed to the residence, where it was totaled. The dealer and the manufacturer were not notified of the failure. The contact received a recall notice of NHTSA Campaign Number: 21V158000 (Air Bags), that he related to the failure. The failure mileage was approximately 130,000.
- Structure › Body · Unknown or other
My boyfriends mom was up north driving and the latch on the driverside door stopped working. She's 60+ and still years later has to tie her door close and climb over the passenger seat to get in the car. I can get it closed if it's accidentally opened just like an inch but the door absolutely cannot to opened any further.
- Air bags
The contact owns a 2007 Ford Fusion. The contact stated that the vehicle was previously repaired under NHTSA Campaign Number: 17V024000 (Air Bags) however, the failure recurred after the recall repair was performed. The contact stated that while driving at an undisclosed speed, the passenger's side…
The contact owns a 2007 Ford Fusion. The contact stated that the vehicle was previously repaired under NHTSA Campaign Number: 17V024000 (Air Bags) however, the failure recurred after the recall repair was performed. The contact stated that while driving at an undisclosed speed, the passenger's side air bag warning light illuminated. The vehicle was taken back to the dealer, where the passenger's side air bag was replaced a second time. The failure recurred. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 240,000.
- Service brakes
This vehicle was totaled in May 2020. I had numerous and constant brake issues with this car and had much of the brake system (brake pads, rotors, and calipers I believe) replaced within a year of the accident. The accident occurred when I tried to apply the brakes, causing me to hydroplane into an…
This vehicle was totaled in May 2020. I had numerous and constant brake issues with this car and had much of the brake system (brake pads, rotors, and calipers I believe) replaced within a year of the accident. The accident occurred when I tried to apply the brakes, causing me to hydroplane into an oncoming car. My concern is that this could be related to the ABS recall (NHTSA CAMPAIGN ID: 19V904000). Although my vehicle does not appear to be affected by the recall, it seems very similar to the brake issues I experienced.
- Air bags · Seats
Took my car on to check why seat belt light was on after bag replaced. Told there is a sensor under passenger seat that reflects weight in seat that is not working that is used in case accident airbag pressure would be deployed. Light will not turn off on dash and told me out of warranty is not on…
Took my car on to check why seat belt light was on after bag replaced. Told there is a sensor under passenger seat that reflects weight in seat that is not working that is used in case accident airbag pressure would be deployed. Light will not turn off on dash and told me out of warranty is not on repair list… I have 2007 fusion that I can’t sell because of safety light. Who is responsible for that. Service at dealer said sorry can’t help me.. it would be 400.00??? R u kidding .
- Air bags · Service brakes, hydraulic
The contact owns a 2007 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) and 19V904000 (Service Brakes, Hydraulic) however, the local dealer had failed to return the contact's call to schedule an appointment for the recall repair. The contact stated that…
The contact owns a 2007 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) and 19V904000 (Service Brakes, Hydraulic) however, the local dealer had failed to return the contact's call to schedule an appointment for the recall repair. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue and followed up with the dealer; however, the dealer failed to assist. The contact had not experienced a failure. VIN tool confirms parts not available.
- Air bags
Air bag light comes on and stays on -this happened shortly after the car's airbag recall was taken care of- had never had a problem before.
- Air bags
Takata recall. The contact owns a 2007 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a…
Takata recall. The contact owns a 2007 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.
- Service brakes · Vehicle speed control
The contact owns a 2007 Ford Fusion. The contact stated while driving at 60 MPH on a bumpy road, the brake pedal was depressed and the vehicle accelerated unintendedly, hit a high curb, and stopped. The air bags did not deploy. There were no warning lights illuminated. The contact was able to…
The contact owns a 2007 Ford Fusion. The contact stated while driving at 60 MPH on a bumpy road, the brake pedal was depressed and the vehicle accelerated unintendedly, hit a high curb, and stopped. The air bags did not deploy. There were no warning lights illuminated. The contact was able to continue driving. The dealer was notified of the failure and informed the contact that she would need to pay a diagnostic test fee. The vehicle was not diagnosed or repaired. The contact stated that the failure reoccurred while driving. The contact stated while driving in the rain and in the process of changing lanes, the vehicle in front of her stopped at the traffic light. The contact then depressed the brake pedal. However, the vehicle hydroplaned, accelerated, and crashed into the rear of the vehicle in front of her. The air bags did not deploy. The contact sustained severe headaches, neck pain, and knee pain and sought medical assistance. The contact’s friend who was pregnant and occupying the front passenger’s seat sustained back pain. The driver of the other vehicle sustained injuries and sought medical assistance. A police report was filed. The vehicle was towed to a tow lot where it was totaled. The dealer was notified of the failure but did not provide any assistance. The manufacturer was notified of the failure and referred the contact to the dealer. The failure mileage was unknown.
- Electrical system · Engine · Vehicle speed control
I didn’t know or the incident with the car until I purchased and started noticed The way it drives. It do have a problem with acceleration while shifting gears, and also loses power with A/c turned on.
- Air bags · Service brakes, hydraulic
The contact owns a 2007 Ford Fusion. The contact received notification of NHTSA Campaign Numbers: 19V904000 (Service Brakes, Hydraulic) and 21V158000 (Air Bags) however, the parts to do the recall repairs were not yet available. The contact stated that the manufacturer had exceeded a reasonable…
The contact owns a 2007 Ford Fusion. The contact received notification of NHTSA Campaign Numbers: 19V904000 (Service Brakes, Hydraulic) and 21V158000 (Air Bags) however, the parts to do the recall repairs were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that while driving at an undisclosed speed, the brake pedal went to the floorboard while depressed, and then the vehicle lost motive power with the brake fluid message displayed. Additionally, brake fluid leaked onto the engine and there was smoke coming from underneath the hood. The dealer was not made aware of the failure. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 200,000. VIN tool confirms parts not available.
- Air bags
Takata recall. The contact owns a 2007 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) however, the part to do the recall repair was not yet available. The dealer was made aware of the issue. The contact stated that the manufacturer had exceeded a…
Takata recall. The contact owns a 2007 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) however, the part to do the recall repair was not yet available. The dealer was made aware of the issue. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact had not experienced a failure. VIN tool confirms parts not available.
- Unknown or other
The contact owns a 2007 Ford Fusion. The contact stated while driving approximately 55 MPH, the brake pedal had to be depressed with extra effort to stop the vehicle. The ABS, traction control, wrench, and oil lights were illuminated on the instrument panel. The vehicle was taken to a local…
The contact owns a 2007 Ford Fusion. The contact stated while driving approximately 55 MPH, the brake pedal had to be depressed with extra effort to stop the vehicle. The ABS, traction control, wrench, and oil lights were illuminated on the instrument panel. The vehicle was taken to a local mechanic to be diagnosed. The dealer informed the contact that the brakes needed to be replaced. The ABS was replaced. The manufacturer was notified of the failure. The contact related the failure to NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic). The approximate failure mileage was 162,000.
- Air bags
Constituent writes requesting assistance in Ford continually reaching out Regarding the Takata Airbag Recall for a vehicle that was Totaled in 2018.
- Service brakes, hydraulic
The contact owns a 2007 Ford Fusion. The contact received notification of Customer Satisfaction Program Number: 21N11 (Service Brakes, Hydraulic). The contact stated that while starting the vehicle, the brake pedal went to the floorboard while depressed. The contact had to apply force to the brake…
The contact owns a 2007 Ford Fusion. The contact received notification of Customer Satisfaction Program Number: 21N11 (Service Brakes, Hydraulic). The contact stated that while starting the vehicle, the brake pedal went to the floorboard while depressed. The contact had to apply force to the brake pedal to stop the vehicle. The vehicle was taken to the dealer and diagnosed that new brake hoses needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was opened. The failure mileage was approximately 122,000.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Extended Braking Distance
On April 18, 2018, the Office of Defects Investigation (ODI) opened Engineering Analysis (EA) 18-002 to investigate reports of braking concerns in model year (MY) 2006-12 Ford Fusion and Lincoln MKZ, and MY 2006-11 Mercury Milan vehicles manufactured with Continental Automotive System?s ABS hydraulic control units…
On April 18, 2018, the Office of Defects Investigation (ODI) opened Engineering Analysis (EA) 18-002 to investigate reports of braking concerns in model year (MY) 2006-12 Ford Fusion and Lincoln MKZ, and MY 2006-11 Mercury Milan vehicles manufactured with Continental Automotive System?s ABS hydraulic control units (HCUs). Complainants report that after an ABS braking event (initiated by slippery or uneven surfaces) the brake pedal moved towards the floor and the vehicle stopping distance increased beyond driver expectations.Inside the HCU are four hydraulic normally closed (NC) valves with zinc-coated moving armatures that control the flow of brake fluid. Unstable brake fluid can degrade over time, allow the brake fluid to gel, and corrosion to form on the armatures. The high-viscosity gelation and corrosion can cause the armatures to become stuck (open). In some cases, braking returns to normal when the armature(s) subsequently become unstuck. The intermittent condition proves difficult to diagnose with complainants reporting having (non-HCU) repairs conducted only to have the condition return.During the investigation, 14 HCUs from complaint vehicles were recovered, including seven from reported crashes. NHTSA?s Vehicle Research and Test Center (VRTC) disassembled the HCUs, removed the four NC valves in each, and confirmed 22 of the 56 NC valves contained stuck armatures. On seven of the 14 HCUs, both front wheel armatures were stuck, on nine of the 14 HCUs two or three armatures were stuck. And 52 of the 56 NC armatures exhibited corrosion of the zinc coating. Forces required to extract stuck armatures from the valve sleeve were measured to range from 1.1 to 18.0 lbs. VRTC also conducted ABS braking tests on a variety of test surfaces that showed HCU failures cause increases in pedal travel and braking distances. Testing also showed that if the driver was able to apply four times the brake pedal force and two times the brake pedal travel, then high-vehicle decelerations could be achieved, however, single or multiple wheel lockups were also occurring.Based on Ford?s response to ODI?s July 20, 2018 information request letter, and complainants' reports to NHTSA, ODI identified a population of vehicles with an elevated level of field failure compared to vehicles produced both before and after.Further evaluation of Ford?s response identified that the brake fluid used to produce these vehicles, a specific formulation of a DOT3 fluid provided by CCI Corporation between February 2006 and July 2009, differed from the brake fluid used in other vehicle populations. ODI used the correlation of fluid specification and elevated field failures to identify a vehicle population exhibiting a defect trend. The complaints, crashes and injuries cited above, and the 14 recovered HCUs involve vehicles from this population.On December 18, 2019, Ford submitted safety recall (19V-904) to remedy HCU failures on the MY 2006-2010 Ford Fusion, Lincoln MKZ, and Mercury Milan vehicles manufactured with the suspect CCI brake fluid formulation. Ford will function test the HCU and replace the DOT 3 brake fluid with an improved DOT 4 brake fluid. If the HCU fails the function test, Ford will install an HCU with a different armature coating (black oxide). HCUs with black oxide coating were fully phased into Ford?s new vehicle production by MY 2016; these HCUs do not appear to be experiencing armature corrosion. ODI notes that the non-recalled EA18-002 subject vehicles, which were manufactured with a different specification brake fluid, did not display an elevated level of field failures like the recalled vehicles.Based on available information, Ford?s rec
- Extended Braking Distance
On December 20, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation (PE) 16-017 to investigate reports of braking concerns in model year 2007 through 2009 Ford Fusion and Mercury Milan vehicles.Complainants report that after an ABS braking event (caused by braking on a slippery or uneven…
On December 20, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation (PE) 16-017 to investigate reports of braking concerns in model year 2007 through 2009 Ford Fusion and Mercury Milan vehicles.Complainants report that after an ABS braking event (caused by braking on a slippery or uneven surface) the brake pedal moved towards the floor and the distance in which the vehicle stopped increased beyond what was expected by the driver.The cause of the problem appears to be the Antilock Braking System (ABS) Hydraulic Control Unit (HCU), a component manufactured for Ford by Continental Automotive Systems.Hydraulic control valves within the HCU can experience corrosion and become stuck.In some cases, braking returns to normal when the valve(s) subsequently become unstuck.The intermittent condition proves difficult to diagnose and complainants report having several brake system components replaced only to have the condition return.ODI has identified 544 reports submitted to the agency that relate to this issue in model year 2006-2012 Ford Fusion/MKZ and MY 2006-2011 Mercury Milan, the subject vehicles.Complainants report an increase in pedal travel which in some cases resulted in going past expected stopping points or having to steer to avoid contacting another vehicle; twenty six report a crash with 3 injuries alleged.The Ford reports shown above, which are from PE16-017 and involved the scope discussed above, were similar in content and identified 7 crashes without injury.During PE16-017, ODI was able to recover HCUs from some complaint vehicles, including some from the reported crashes.The recovered HCUs were sent to NHTSA's Vehicle Research and Test Center (VRTC) in East Liberty, Ohio for evaluation.VRTC was able to confirm stuck valves and corrosion of the zinc coated control valves, and it's testing indicates that HCU failures cause increases in pedal travel that may affect braking distance.According to Ford, newer version HCUs have a different coating on the affected valves that do not currently appear to be experiencing corrosion.In it's response to ODI's information request letter, Ford described analysis of two failed HCUs removed from complainant vehicles.In both cases, a gelatinous material found inside the HCU prevented control valves from properly returning to the closed position after actuation.Ford found that an interaction between the valve coating and brake fluid was the likely source of the gelatinous material.It acknowledged that stuck valves can result in increased pedal travel but maintains the affected brake circuit will develop pressure and respond if the brake pedal is pressed sufficiently.While it has not identified an unreasonable risk to safety due to this issue, Ford states that it continues to investigate the possible causal and contributory factors including additional engineering evaluations and testing.An Engineering Analysis has been opened to assess the scope, frequency, and safety-related consequence of the alleged defect.Based on information received during PE16-017, the scope of the investigation has been increased to include another model, the Lincoln MKZ, and to expand the model years of the subject vehicles.
- Floor mat interference with accelerator
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…
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.
- Tire valve cracking
On october 14, 2008, odi opened pe08-060 to investigate allegations of cracked and leaking snap-in tire valves in model year (my) 2007 vehicles manufactured by ford motor company.the valves were supplied to ford by topseal auto-parts, a subsidiary of the shanghai baolong automotive corporation in china.valves made by…
On october 14, 2008, odi opened pe08-060 to investigate allegations of cracked and leaking snap-in tire valves in model year (my) 2007 vehicles manufactured by ford motor company.the valves were supplied to ford by topseal auto-parts, a subsidiary of the shanghai baolong automotive corporation in china.valves made by topseal for aftermarket sale were the subject of two recent safety recalls by tech international (08t-018) and dill air controls (08t-028), the latter of which was investigated by odi in pe08-036 and ea08-022.the defect conditions addressed by the aftermarket tire valve recalls both involved inadequate resistance to ozone cracking due to issues with the supply of anti-ozonant chemicals to topseal for a period from july to mid-november 2006.the aftermarket valves were compounded with a blend of epdm and natural rubber, using a relatively low percentage of epdm (epdm provides inherent resistance to ozone cracking).hence, the need for anti-ozonant chemicals and the problems with cracking when those chemicals were missing or out of specification in some lots of valves.both recall campaigns involved inspection programs to identify and replace valves with visible surface cracking.although the topseal valves supplied to ford also appear to have been affected by the anti-ozonant supply issues in mid to late-2006, ford indicated that its valves were made at a different topseal production line and were compounded with a higher percentage of epdm rubber to meet more stringent specifications from ford.odi's analysis of complaint and warranty data provided by ford showed that problems with cracked tire valves were significantly higher for my 2007 vehicles produced from december 2006 through march 2007.ford responded by implementing changes in its material specifications for snap-in rubber tire valves and also increasing the quality and acceptance standards for valves imported for use in its vehicles.while the complaint and warranty claim rates are elevated for subject vehicles produced from december 2006 through march 2007, the rates of leaking valves are well below one percent of production for each of the peak months for all of the affected models.a substantial majority of the subject vehicles are equipped with tire pressure monitoring systems (TPMS) which warn the driver when any tire pressures drops below 25 percent of recommended inflation pressure. As outlined in a letter to odi dated april 6, 2009, ford has agreed to send letters to owners of certain my 2007 and 2008 ford, lincoln and mercury vehicles to provide information about the cracking concern. Letters will be sent to owners of vehicles built from november 2006 through may 2007.owners can opt for a free dealer inspection.valves exhibiting surface cracks or air leakage related to ozone attack will be replaced by ford under its normal warranty terms.ford expects to send the letter by approximately mid-may 2009. Based on the use of TPMS in the majority of subject vehicles and the relatively low rates of repairs associated with leaking valves and resultant tire damage, odi believes that the actions ford has agreed to take will provide effective and expeditious resolution for vehicles that were built during the period when valves with inadequate resistance to ozone cracking were most likely to have been used in vehicle production.further investigation of this matter would not be an efficient allocation of agency resources.accordingly, this investigation IS closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will continue to
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10250305When performing any transmission fluid change or topoff involving Motorcraft Premium ATF, MERCON V has replaced all versions of Motorcraft Premium ATF and can be used going forward. Mixing Motorcraft Premium ATF and MERCON V in the same transmission is acceptable. After 31-Jan-2024, Motorcraft Premium ATF will no longer be manufactured and will only be available until inventory depletes.
- 10240415Certain 2005-2014 Mustang, 2005-2006 GT, 2004-2011 Ranger, 2006-2012 Fusion and MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge & MKX Vehicles Driver & Passenger Airbag Module Quality Control Inspection REASON FOR THIS SUPPLEMENT Updated Ranger Technical Information to include images of a pass and fail airbag inflator inspection for 2007-2011 model years.
- 10209374Certain 2005-2014 Mustang, 2005-2006 GT, 2004-2011 Ranger, 2006-2012 Fusion & MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge & MKX Vehicles Driver & Passenger Airbag Module Quality Control Inspection: Ford Motor Company has determined that some vehicles claimed by dealers as repaired under Takata Airbag Safety Recalls 15S21, 17S42, 18S02, 19S01, and 21S12 may not have received the claimed repairs. The propellant in certain Takata airbag inflators can experience an alteration over time with exposure to certain climate conditions. A combination of time, high temperature fluctuations, and humidity contribute to the degradation of the propellant in the inflators. This degradation can cause the propellant to burn too quickly, creating high pressure inside the inflator, and in extreme cases causing the inflator to rupture in the event of a crash necessitating airbag deployment. A ruptured inflator can send inflator parts toward vehicle occupants resulting in serious injury or death. Additional information regarding Takata recalls can be found at www.nhtsa.gov and www.safercar.gov.
- 10205727Certain 2006-2010 Model Year Fusion/Milan/MKZ/Zephyr Vehicles Equipped with Anti-Lock Brake Systems DOT 3 Brake Fluid and Anti-Lock Brake System Function In some of the affected vehicles, customers may return to the dealer with complaints of extended brake pedal travel after either 19S54 or 20S14 was previously performed and the program is closed
- 10140334Certain 2006-2008 Model Year Fusion and Milan, 2006 Zephyr, 2007-2008 MKZ and 2007-2008 Edge, MKX and Ranger Vehicles - Driver Airbag Inflator Replacement
- 10138535Certain 2006-2008 Model Year Fusion and Milan, 2006 Zephyr, 2007-2008 MKZ and 2007-2008 Edge, MKX and Ranger Vehicles - Driver Airbag Inflator Replacement
- 10125092Certain 2006-2008 Model Year Fusion and Milan, 2006 Zephyr, 2007-2008 MKZ and 2007-2008 Edge, MKX and Ranger Vehicles - Driver Airbag Inflator Replacement
- 10109070The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
- 10057723Ford: a job aid was developed and now available for the ptu internal or external fluid leakage for all wheel drive vehicles.
- 10052190Ford/lincoln/mercury: some vehicles, with diagnostic codes (dtcs) p0351, p0352, p0353, p0354, p0355, may experience a malfunction indicator lamp in the powertrain control module (pcm) and one or more coil on plug(s) damage. Models 2006-08 milan, fusion, 2008 sable, taurus, 2007-08 MKZ, MKX, edge, 2006 zephyr.
- 10048099Ford/lincoln/mercury: may have sludge buildup in throttle body leading to less airflow or engine idling rpm fluctuation and hard starts or battery disconnect or dead battery after keep alive memory (kam) clear. Models 2003-05 thunderbird, 05-06 mustang, 06-08 fusion, 04-05 explorer, 05-06 expedition, 05-07 F-150; 2003-06 LS, 06 zephyr, 05-06 navigator; 06-08 milan.
- 10039053Ford: if there IS an intermittent lack of power, surge, or hesitation while driving the brakes will override acceleration.
- 10023866Mil on--dtc p2100 and p2110 in memory - 3.0L engine.
- 10022284Front seat manual lumbar inoperative.
- 10021277Various driveability/transmission symptoms - pcm/tcm calibration updates 3.0L - aisin F21 auto trans.
- 10021223Certain 2007 vehicles built between july 1, 2006 - september 2, 2006 are not included in the oasis. Vehicles affected have owner guides with power distribution box fusing information that does not match the vehicle.
- 10021218Power steering fluid leaks from steering rack and pump attachment joints. Updated 2/27/08.
- 10021051Possible engine damage - install special service tools prior to removing crankshaft pulley bolt.
- 10021046Driveability concerns and/or dtcp0340 - inspect crankshaft pulley.
Every Ford Fusion model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.