2008 Ford Fusion
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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These records cover every 2008 Ford Fusion. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
6 recalls name the 2008 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 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to…
Risk and remedy
Risk
In the event of a crash necessitating deployment of the frontal air bag, 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 inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.
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
1,353 complaints53 involved a crash6 involved a fire29 injuries
What owners report most
Latest complaints
- Service brakes
I had the Ford brake recall work completed in 2023, but the same brake issue has returned. This appears to be the same HCU problem covered by the recall, and Ford is now refusing to repair it. I am concerned because this is a serious safety issue, and the recall repair did not permanently correct the problem.
- Service brakes
I have been having issues with my 2008 ford fusion. I did research and found that the is a Ford customer satisfaction program( campaign # 21N11) which also goes along with recall number 19S54 and ford is refusing to fix the issues. Their lots of complaints and somethingd needs to be done ASAP before someone gets hurt cause this has to do with the brakes.
- Service brakes
My brake pedal drops to the floor when braking at times. Mechanics say that is my ABS module. I believe this is a very common issue with these vehicles. This has happened to me several times. Only remedy without repair is disengaging the ABS system all together. There has not been a recall on…
My brake pedal drops to the floor when braking at times. Mechanics say that is my ABS module. I believe this is a very common issue with these vehicles. This has happened to me several times. Only remedy without repair is disengaging the ABS system all together. There has not been a recall on this but there has been a customer satisfaction program associated with the brake system. I tried to have mine fixed and Ford says the program has expired. I feel like braking is the most important thing you need to be on the road. This needs to be a full recall and not a satisfaction program. Thank you
- Service brakes
Have to press down hard on brakes to slow or stop. Had landmark ford inspect recall issue & they stated nothing was wrong with brakes.
- Service brakes
took in for two recalls to Serramonte ford, airbag recall fixed, braking issue not fixed due to as dealer put it, issues with computer system and was not given a timeframe to have it completed, vehicle was returned to me.
- Structure › Body
Door handle is stuck/broken. Door cannot open from the inside or outside. Passengers are stuck in car.
- Service brakes
The vehicle brakes will engage at random intervals without the brake pedal being touched. This happens at all speeds, and even at a stop. Issue still occurs daily, and has been ongoing for 5+ years. Brake master cylinder and aux boost pump have been replaced twice with OEM parts, and three complete…
The vehicle brakes will engage at random intervals without the brake pedal being touched. This happens at all speeds, and even at a stop. Issue still occurs daily, and has been ongoing for 5+ years. Brake master cylinder and aux boost pump have been replaced twice with OEM parts, and three complete brake jobs (pads, calipers and rotors) in the last 5 years. At slower speeds, it manifests as a drag to forward motion. At higher speeds, the drag is more pronounced, and causes the car to decelerate. It has also caused the tires to "hop" during travel, causing loss of vehicle control. Luckily, no accidents so far. I am aware of the recall for the HCU (ABS Module) for this vehicle, but four different Ford dealerships have declined to examine closer, citing recall 19S54 as a "customer experience" issue, not a safety issue. The brake fluid replacement (DOT3 to DOT4) has been done, but dealer declined to examine or replace the HCU, citing "out of warranty".
- Unknown or other
This isn't an incident. I just want to report that Ford Motors will not replace the Hydraulic Control unit that is under recall for my 2008 Ford Fusion. They will only replace cars that are 15 or less years old. My car has 117,000 miles on it. Far less than the yearly average of 14,000 miles. If…
This isn't an incident. I just want to report that Ford Motors will not replace the Hydraulic Control unit that is under recall for my 2008 Ford Fusion. They will only replace cars that are 15 or less years old. My car has 117,000 miles on it. Far less than the yearly average of 14,000 miles. If this truly a safety issue, then I feel that my car should be serviced under the recall. I chatted with the Ford Customer service rep and he informed me that it was safe to drive, But he did tell me to take it to a Ford dealer (of course) and that I would be financially responsible for the repair. So I own a vehicle that is under a recall, but since it's 1 year past the 15 year ownership date, Ford will not repair it under the recall. Thus any Ford owner that owns a vehicle that is older than mine is also out of luck Thank you for taking the time to read this and maybe encourage Ford to do the right thing. My car should not be any less safe than a 2010 car
- Steering · Structure › Body · Suspension
I want to file a safety complaint against Ford car company for their vehicle in which I purchased which is a 2008 Ford Fusion SEL for excessive and dangerous rot and rust problem on the frame and suspension and under component which can lead to accidents if one of these components fall apart . I…
I want to file a safety complaint against Ford car company for their vehicle in which I purchased which is a 2008 Ford Fusion SEL for excessive and dangerous rot and rust problem on the frame and suspension and under component which can lead to accidents if one of these components fall apart . I purchased a 2008 Ford fusion SEL in Connecticut which used to be a Massachusetts state government vehicle before I've obtained it. It was well maintenance and had no flood damage. But just like a wide range of cars from Ford especially this model that I've purchased has a serious problem with excessive rust which make the car very dangerous to drive. Mind's speaking I've had to have framework done to my vehicle and change multiple suspension parts because of all the rust my transmission pan literally fell apart and all the oil came because it was so rusted. My stabilizer links and control arms have fell apart in which obstructs the steering which also caused a safety hazard for me and other people on the road. Ford has a duty to design their cars with a certain level of weather resistance. After doing research I found that there is a wide range of customers who's having the same having the same problems with this year make and model just like other vehicles that are made by ford. All the problems that stated in this complaint having verified by ASE certified mechanics that I've been working on my vehicle. The contact stated all the original metal components like control arms, tie rods, suspension shocks and struts and frame all have a issue with rot rust and corrosion which led to vehicles having alignment issues.
- Service brakes, hydraulic
The contact owns a 2008 Ford Fusion. The contact stated that while his girlfriend was driving at undisclosed speeds, the vehicle hydroplaned, and the anti-lock brakes engaged and disengaged. The brake pedal became inoperable. The vehicle was taken to the local dealer, where it was determined that…
The contact owns a 2008 Ford Fusion. The contact stated that while his girlfriend was driving at undisclosed speeds, the vehicle hydroplaned, and the anti-lock brakes engaged and disengaged. The brake pedal became inoperable. The vehicle was taken to the local dealer, where it was determined that the vehicle had passed testing. The vehicle was repaired, but the failure recurred. While driving the vehicle, the brake pedal was squishy and would depress to the floorboard. The contact stated that the solenoid was stuck open. There were no warning lights illuminated. The manufacturer was contacted, but no assistance was provided. The contact stated that the failure was related to NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic). The failure mileage was approximately 79,259.
- Unknown or other
The dashboard has warped. The seems on the dashboard around the passenger side airbag cover have become partially unattached to the rest of the dashboard and have caused an opening above passenger side airbag that may allow for debris/dirt to enter into safety equipment and could potentially lead…
The dashboard has warped. The seems on the dashboard around the passenger side airbag cover have become partially unattached to the rest of the dashboard and have caused an opening above passenger side airbag that may allow for debris/dirt to enter into safety equipment and could potentially lead to serious hazards to person if airbag unit deploys. The plastic vent and sensor under the windshield located in the very top front of the dashboard has cracked and has also become dislodged and lifteb from dashboard housing and can pose safety issues if in a collision. There is also some notable brittleness arising in the dashboard material. The warping of the dashboard and its components pose strong safety concerns and a risk to service departments doing recall repairs for manufacturers. There are many similar vehicles produced by this manufacturer during this time that have had same dashboard failures and at the very least it was been the root of stress anxiety for owners and repair dealerships.
- Engine · Engine and engine cooling
The contact owns a 2008 Ford Fusion. The contact stated that while driving approximately 55 MPH, the check engine warning light illuminated. The message that the engine was overheated was displayed. The vehicle was towed to the local dealer, where it was diagnosed that coolant had leaked into the…
The contact owns a 2008 Ford Fusion. The contact stated that while driving approximately 55 MPH, the check engine warning light illuminated. The message that the engine was overheated was displayed. The vehicle was towed to the local dealer, where it was diagnosed that coolant had leaked into the compression chamber and the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 68,000. The VIN was not available.
- Forward collision avoidance › Automatic emergency braking · Service brakes · Unknown or other
I just bought this car and the brakes do not feel right when i go to stop. They are new and i got them changed today and it still makes a pop noise.
- Electrical system · Exterior lighting
I discovered my drivers rear brake light bulb melted in their socket. The socket themselves are burnt black and the drivers side tail light case has been hot enough to melt. A quick search on the Internet turns up a lot more chatter about this same issue. Even scarier is the fact that this…
I discovered my drivers rear brake light bulb melted in their socket. The socket themselves are burnt black and the drivers side tail light case has been hot enough to melt. A quick search on the Internet turns up a lot more chatter about this same issue. Even scarier is the fact that this happening with zero warning. No blown fuse, no codes, nothing to indicate your frying stuff in the back at all. The dealership denies hearing anything , Ford denies hearing anything, even though it's happening all over the country and I found at least five other complaints listed with the National Highway Traffic Safety Administratiion. I took car in for oil change and discovered this but want $250 for repair and no guarantee it won't happen again. I'm a senior with limited income and it's a 2008 Ford fusion SE HELP NEED RECALL!
- Engine · Power train
The contact owns a 2008 Ford Fusion. The contact stated that there was a squealing sound coming from underneath the dashboard. The vehicle was hard shifting while accelerating or while idling. The check engine warning light was illuminated. The vehicle was taken to the dealer who was unable to…
The contact owns a 2008 Ford Fusion. The contact stated that there was a squealing sound coming from underneath the dashboard. The vehicle was hard shifting while accelerating or while idling. The check engine warning light was illuminated. The vehicle was taken to the dealer who was unable to identify the cause of the failure. The vehicle had not been repaired. The failure persisted and the vehicle was taken to the dealer approximately 8-times. The manufacturer was made aware of the failure and confirmed that the vehicle was not included in TSB Number: 10052190 (Power Train). The approximate failure mileage was 143,300. The repairs were made at the owner's expense in the amount of $2196.46.
- Service brakes
Driving around 55 and put brakes on and went 3/4 to floor like they were out. 2 other people experienced the same. HCA Unit must be bad or corrosive. I read online about this. Ford has extended warranty recall and sent letter and fluid changed 14 yes later. We'll that's a little late cause…
Driving around 55 and put brakes on and went 3/4 to floor like they were out. 2 other people experienced the same. HCA Unit must be bad or corrosive. I read online about this. Ford has extended warranty recall and sent letter and fluid changed 14 yes later. We'll that's a little late cause obviously unit bad now. Ford dealer will not replace cause can't duplicate problem. If I wreck, Ford is liable for 4 to 5 people in car. Common sense would be REPLACE PART!!!
- Service brakes, hydraulic
The contact owns a 2008 Ford Fusion. The contact stated while driving 50 MPH, the brake pedal was depressed and went to the floorboard. The contact was unsure if a warning light was illuminated. The contact pumped the brake pedal several times, and the brake pedal started operating normally. The…
The contact owns a 2008 Ford Fusion. The contact stated while driving 50 MPH, the brake pedal was depressed and went to the floorboard. The contact was unsure if a warning light was illuminated. The contact pumped the brake pedal several times, and the brake pedal started operating normally. The vehicle was taken to the dealer for diagnostic test; however, the dealer stated that no failure was found. The manufacturer was contacted but offered no assistance. The failure mileage was 73,000.
- Power train
Transmission slipping
- Service brakes, hydraulic
The contact owns a 2008 Ford Fusion. The contact received notification of NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair.…
The contact owns a 2008 Ford Fusion. The contact received notification of NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic) however, the part to do the recall repair was unavailable. 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. The contact had not experienced a failure. VIN tool confirms parts not available.
- Latches/locks/linkages · Latches/locks/linkages › Trunk lid › Latch
The contact owns a 2008 Ford Fusion. The contact stated that the trunk latch was inoperable. The failure nearly caused the trunk to slam on her hand. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure. The failure mileage was approximately 98,000.
- Service brakes, hydraulic
The contact owns a 2008 Ford Fusion. The contact stated while driving at an undisclosed speed, the vehicle drove over a bump in the roadway and the contact depressed the brake pedal however, the vehicle failed to stop immediately. The contact depressed the brake pedal to the floorboard, and the…
The contact owns a 2008 Ford Fusion. The contact stated while driving at an undisclosed speed, the vehicle drove over a bump in the roadway and the contact depressed the brake pedal however, the vehicle failed to stop immediately. The contact depressed the brake pedal to the floorboard, and the vehicle came to a complete stop. No warning lights were illuminated. The vehicle was taken to a local dealer; however, the dealer was unable to duplicate the failure. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 151,000.
- Service brakes, hydraulic
The contact owns a 2008 Ford Fusion. The contact stated while driving 20 MPH and driving over a black ice, the contact felt the brake pedal had lost pressure. The contact desperately pushed on the brake pedal for the vehicle to stop. The vehicle was taken the dealer and the contact was informed…
The contact owns a 2008 Ford Fusion. The contact stated while driving 20 MPH and driving over a black ice, the contact felt the brake pedal had lost pressure. The contact desperately pushed on the brake pedal for the vehicle to stop. The vehicle was taken the dealer and the contact was informed that the brake fluid was low, and that the hydraulic control unit (HCU) needed to be replaced; but the failure reoccurred. The vehicle was taken to the dealer, but no failure was found. The manufacturer was contacted and referred the contact to the NHTSA Hotline. The failure mileage was 128,000.
- Air bags
Takata recall. The contact owns a 2008 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair.…
Takata recall. The contact owns a 2008 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) however, the part to do the recall repair was unavailable. 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 dealer had been contacted but had not returned the phone calls. The contact had not experienced a failure. Parts distribution disconnect. The consumer stated there is another recall mentioned but not listed.
- Service brakes, hydraulic
The contact owns a 2008 Ford Fusion. The contact stated while driving at various speeds and depressing the brake pedal, the brake pedal went down to the floorboard. There was no warning light illuminated. The contact received notification of NHTSA Campaign Number: 19V904000 (Service Brakes…
The contact owns a 2008 Ford Fusion. The contact stated while driving at various speeds and depressing the brake pedal, the brake pedal went down to the floorboard. There was no warning light illuminated. The contact received notification of NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic) and the vehicle was taken to the dealer for the recall repair. However, upon inspecting the vehicle, the dealer informed the contact that the vehicle had passed inspection and did not need to be repaired under the recall. The dealer then marked the recall as complete. The vehicle was not repaired. The manufacturer was notified of the failure but provided no assistance and referred the contact to the NHTSA Hotline. The failure mileage was approximately 200,000.
- Air bags
The contact owned a 2008 Ford Fusion. The contact received notification of NHTSA Campaign Number: 21V158000 (Air Bags) and would like to be removed from the recall distribution list as the vehicle had been totaled. The local dealer was not contacted. The manufacturer was contacted.
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.
- Accel Pedal Interference - Acc Floormat
Unsecured mats may interfere with accelerator pedal return to idle. A heel blocker in the floor pan provides a platform that may lift an unsecured mat into contact with the pedal. Ford introduced new pedals as a running change early in model year (MY) 2010 vehicles. Analysis of complaints received by ODI and Ford show…
Unsecured mats may interfere with accelerator pedal return to idle. A heel blocker in the floor pan provides a platform that may lift an unsecured mat into contact with the pedal. Ford introduced new pedals as a running change early in model year (MY) 2010 vehicles. Analysis of complaints received by ODI and Ford show elevated rates of pedal entrapment incidents in MY 2008 through early 2010 production vehicles. Incidents typically occur following hard pedal applications to pass slower traffic or when merging into faster traffic. Drivers allege continued high engine power after releasing the accelerator pedal and difficulty braking, including reports that the incident was controlled by shifting to neutral or turning the engine off. Drivers and service technicians reference observing evidence of mat interference or note unsecured Ford or aftermarket all weather floor mats in post-incident inspections.Based on information gathered during the Preliminary Evaluation the population being investigated has been narrowed to model years 2008 to 2010.This investigation has been upgraded to an engineering analysis on MY 2008 through early-2010 vehicles (produced through September 2009) to further assess the scope, frequency and safety consequences of the alleged defect.The VOQs associated with the opening of this Engineering Analysis are: 10479693, 10415911, 10379562, 10372674, 10345830, 10342572, 10339330, 10335336, 10334211, 10332233, 10331160, 10329659, 10327597, 10320011, 10232027, 10214131
- 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.
- 10254138All accessory stick-on keyless entry keypads come with a wallet card containing the master code. If the accessory keypad was factory installed, this card will be placed in the glove box and should be handed to the vehicles owner during initial delivery. Unlike the integrated (wired) factory keypad, the accessory keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool. If the wallet card for an accessory keypad is lost, follow these steps to recover the code. Dealer Key Code access is granted through the Dealer Program Enrollment System (DPES); dealership management can authorize users. The authorized user must go to FMCDealer.com > Parts and Service > Parts Product Line Information > Keys/Entry Devices > Aftermarket Keyless Entry Keypad Code Access. Follow the instructions on the screen to obtain the master code for the accessory keypad.
- 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
- 10140323The Accessory (Wireless) Keyless Entry Keypad can only be used with vehicles that are factory built with Remote Keyless Entry (RKE). The master code for the Accessory (Wireless) Keyless Entry Keypad can be retrieved from FMCDealer - Parts and Service - Parts Product Line Information - Keys/Entry Devices - Aftermarket Keyless Entry Keypad Code Access. Access to this site is granted through Dealer Program Enrollment System (DPES) and Dealer Principal, General Manager or Parts and Service Director can authorize users. Once authorized the retrieval process for master code can be obtained. The master code for the Accessory Keyless Entry Keypad cannot be retrieved from the body control module(BCM) with a diagnostic tool.
- 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
- 10138524The Accessory (Wireless) Keyless Entry Keypad can only be used with vehicles that are factory built with Remote Keyless Entry (RKE). The master code for the Accessory (Wireless) Keyless Entry Keypad can be retrieved from FMCDealer - Parts and Service - Parts Product Line Information - Keys/Entry Devices - Aftermarket Keyless Entry Keypad Code Access. Access to this site is granted through Dealer Program Enrollment System (DPES) and Dealer Principal, General Manager or Parts and Service Director can authorize users. Once authorized the retrieval process for master code can be obtained. The master code for the Accessory Keyless Entry Keypad cannot be retrieved from the body control module(BCM) with a diagnostic tool.
- 10137113Replacing the original equipment SYNC/Navigation system with either an aftermarket SYNC/Navigation kit or modifying original SYNC/Navigation parts to provide additional features is not recommended nor supported on any Ford, Mercury or Lincoln vehicle. Only approved Genuine Ford accessories or originally installed systems are supported and certified to function correctly with other vehicle systems. If you suspect a system has been modified, the following resources can be used to verify original equipment: Monroney Label (Window Sticker), Professional Technician Society (PTS) OASIS tab select SYNC or HVBOM. For Genuine Ford accessories use: PTS Workshop Tab select Dealer Installed Accessory or Accessory Installation.
- 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.
- 10095184Replacing the original equipment sync/navigation system with either an aftermarket sync/navigation kit or modifying original sync/navigation parts to provide additional features IS not recommended nor supported on any ford, mercury or lincoln vehicle. Only approved genuine ford accessories or originally installed systems are supported and certified to function correctly with other vehicle systems. If you suspect a system has been modified, the following resources can be used to verify original equipment: monroney label (window sticker), professional technician society (pts) oasis tab select sync or hvbom. For genuine ford accessories use: pts workshop tab select dealer installed accessory or accessory installation.
- 10091151Some 2008-2017 ford/mercury/lincoln vehicles equipped with sync may generate a vhr that identifies a concern with the brakes and suspension category indicating service IS required due to a brake system warning lamp being illuminated. If the park brake was applied when the vhr was gathering data from the major vehicle systems, the brakes and suspension message will be reported as the vhr looks for any warning lamps illuminated in the instrument cluster. Rerun the vhr with the engine on and vehicle in park, and ensure the park brake IS disengaged. If the sync vhr IS still reporting a concern to the customers sync owners account, refer to the appropriate workshop manual section for diagnosis by dtc or symptom. Starting in 2015 not all sync equipped vehicles support vhr, refer to the owners manual for vhr operation.
- 10090681Some 2008-2017 ford/mercury/lincoln vehicles equipped with sync may generate a vhr that identifies a concern with the brakes and suspension category indicating service IS required due to a brake system warning lamp being illuminated. If the park brake was applied when the vhr was gathering data from the major vehicle systems, the brakes and suspension message will be reported as the vhr looks for any warning lamps illuminated in the instrument cluster. Rerun the vhr with the engine on and vehicle in park, and ensure the park brake IS disengaged. If the sync vhr IS still reporting a concern to the customers sync owners account, refer to the appropriate workshop manual section for diagnosis by dtc or symptom. Starting in 2015 not all sync equipped vehicles support vhr, refer to the owners manual for vhr operation.
- 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.
- 10021218Power steering fluid leaks from steering rack and pump attachment joints. Updated 2/27/08.
Every Ford Fusion model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.