2009 Ford Fusion
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › Fusion › 2009
These records cover every 2009 Ford Fusion. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
7 recalls name the 2009 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 2013 Ford Mustang vehicles sold, or ever registered in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, Ford is recalling…
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
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. 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 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
1,023 complaints65 involved a crash5 involved a fire40 injuries
What owners report most
Latest complaints
- Service brakes, hydraulic
The contact owns a 2009 Ford Fusion. The contact stated that while driving 20 MPH and coming to a complete stop at a traffic light, the brake pedal was depressed but traveled down to the floorboard. The contact shifted into neutral(N) and continued to pump the brake pedal until the vehicle…
The contact owns a 2009 Ford Fusion. The contact stated that while driving 20 MPH and coming to a complete stop at a traffic light, the brake pedal was depressed but traveled down to the floorboard. The contact shifted into neutral(N) and continued to pump the brake pedal until the vehicle responded. The vehicle was taken to the dealer to be repaired under NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic). The brake calipers and the brake master cylinder were replaced, and the ABS module was cleaned; however, the failure persisted, and the contact was advised to retrieve the vehicle. The contact believed that the ABS module replacement was required to repair the vehicle, but the dealer denied additional repairs.
- Service brakes
Dear NHTSA, The braking system failed which was covered by Ford Safety Recall 19S54 with NHTSA campaign #19V904000 at 37,750 miles. After research and finding the label of the ABS Hydraulic Control Unit still on the vehicle, being manufactured 07/12/2008, picture attached, it turned out to be…
Dear NHTSA, The braking system failed which was covered by Ford Safety Recall 19S54 with NHTSA campaign #19V904000 at 37,750 miles. After research and finding the label of the ABS Hydraulic Control Unit still on the vehicle, being manufactured 07/12/2008, picture attached, it turned out to be the original HCU, whose failures were the reason for the Safety Recall. A Ford dealer had performed software evaluation of the ABS HCU and determined replacement of unit not necessary. This was done on 4/14/2021 at 17,606 miles along with break fluid change to DOT4 and reservoir cap change. Unfortunately my wife just went through a four-way stop intersection when the break pedal went to the end of its movement without being able to stop. No injuries or crashes involved. According to all sources read, this was caused by the ABS HCU valve being stuck open after attempting to brake on the slippery road during rain. The car is no longer safe to drive and sitting in front of our home. Asked Ford Motor Co to take care of this incomplete repair by the Ford dealer and replace the HCU but they say it’s no longer their responsibility. My understanding is that with a safety recall, they are to fix the issue as long as the vehicle is still around. They don’t agree. Can you help with this situation? Thank you! Note: I tried to upload pictures of ABS HCU and VIN labels on vehicle but failed after a number of retry attempts. If you need them I can try another way. Let me know.
- Exterior lighting · Service brakes · Suspension
my brakes had went out while i was driving home from work
- Service brakes, hydraulic
The contact owns a 2009 Ford Fusion. The contact stated that the vehicle was taken to an independent mechanic for brake repairs, and after the repairs, the brake pedal felt spongy. The independent mechanic performed further inspections and diagnosed the vehicle with insufficient brake pressure due…
The contact owns a 2009 Ford Fusion. The contact stated that the vehicle was taken to an independent mechanic for brake repairs, and after the repairs, the brake pedal felt spongy. The independent mechanic performed further inspections and diagnosed the vehicle with insufficient brake pressure due to a failure of the ABS hydraulic control unit. The manufacturer was notified of the failure. The contact related the failure to NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic); however, the VIN was not included. The approximate failure mileage was 110,000.
- Service brakes, hydraulic
The contact owns a 2009 Ford Fusion. The vehicle was repaired under NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic), but the failure occurred. When the vehicle was retrieved from the dealer, the contact was informed that the vehicle had passed an inspection. The brake pedal was…
The contact owns a 2009 Ford Fusion. The vehicle was repaired under NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic), but the failure occurred. When the vehicle was retrieved from the dealer, the contact was informed that the vehicle had passed an inspection. The brake pedal was depressed approximately seventy percent down for the brakes to engage. The contact stated that the brake pedal was soft while depressed. No warning lights were illuminated. The vehicle was taken back to the dealer, but it was unknown if the vehicle was diagnosed. The contact was informed that the rear calipers needed to be inspected. However, the contact was unsure if the rear calipers were inspected. The contact stated that the vehicle remained at the dealer unrepaired and was awaiting a flush of the braking system. The dealer made the manufacturer aware of the issue. The zone manager informed the contact that a satisfaction program had expired. No additional assistance was provided. The failure mileage was approximately 95,000.
- Service brakes
The ABS warning light came on while driving, and the brakes began to feel unsafe during normal stops. I later learned there is an open recall for the ABS module on my vehicle. When I took it to the dealership, they refused to perform the recall repair unless I paid out of pocket for a new ABS…
The ABS warning light came on while driving, and the brakes began to feel unsafe during normal stops. I later learned there is an open recall for the ABS module on my vehicle. When I took it to the dealership, they refused to perform the recall repair unless I paid out of pocket for a new ABS control module, even though the recall notice mentions this component. The issue affects braking performance and safety, especially on wet roads. The ABS system continues to malfunction, and the dealership’s refusal to complete the recall repair leaves the vehicle unsafe to drive.
- Service brakes
My car's brake pedal started not working properly. When trying to brake, the brake pedal goes down further than what it is supposed to and it takes longer than normal to brake, causing almost wrecks. It happens suddenly when trying to brake sometimes and it is very scary. There was a previous…
My car's brake pedal started not working properly. When trying to brake, the brake pedal goes down further than what it is supposed to and it takes longer than normal to brake, causing almost wrecks. It happens suddenly when trying to brake sometimes and it is very scary. There was a previous recall on the brake lines and it said they needed to be flushed out and all. I had this done to my car before and thought everything was okay. But it is not. I called Ford and they said there is currently a Customer Satisfaction Program that covers the repair of the Hydraulic control unit but it is limited to vehicles under 15 years old. My car is 16 years old so it does not qualify for this program. I asked why this wasn't a recall because it is such a big safety issue and they stated they couldn't make it a recall, it would have to be reported and issued from NHTSA. If the brakes/brake pedal is messing up and this is a known issue, then the vehicles' age should not matter. It should be recalled and fixed because this is such a huge safety concern and obviously a defect when manufactured. I don't have another car to drive and I'm sure there are numerous others in this same position and I feel it is imperative that this be looked into further and issued as a recall so people can remain safe and I'm sure this would save lives. I almost ran into a car today and it is extremely hazardous. It is very dangerous and scary and there is no warning light or anything indicating anything is wrong until driving it and it randomly happens. I have taken care of my car and had the previous recalls fixed but Ford knows this is an issue and very dangerous so it seems clear this needs to be issued as a recall.
- Service brakes
I have recall 19S54 and called Ford. They made an appointment with Downtown Ford, Charleston, WV. The dealership said ford declined my recall repair due to not being able to get their machines to get any codes from my car. The ABS light is on. My mechanic said Ford should fix their recall. The…
I have recall 19S54 and called Ford. They made an appointment with Downtown Ford, Charleston, WV. The dealership said ford declined my recall repair due to not being able to get their machines to get any codes from my car. The ABS light is on. My mechanic said Ford should fix their recall. The recall says the D03 fluid must be changed to DOT 4 even if no problem found and if problem detected how to fix it! Ford declined because they can't get code reader to work on my car. They said it is a Preexisting Condition! My car is old but only has 24,800 miles and has been kept inside in a heated garage. The Downtown dealership said their hands are tied and would love to make my car safe. Their phone number is 304 344 1601. Please help me get my car fixed!!! I have called Ford multiple times and no help due to not having the codes from the dealership. Thanks!!!!
- Service brakes
I have noticed for some time in our 2009 Ford Fusion purchased used that the brake travel was longer than it should be. This results in the need to anticipate braking quicker and react faster to allow appropriate time to slow down. In doing some research I discovered a Ford recall 19S54 which was…
I have noticed for some time in our 2009 Ford Fusion purchased used that the brake travel was longer than it should be. This results in the need to anticipate braking quicker and react faster to allow appropriate time to slow down. In doing some research I discovered a Ford recall 19S54 which was apparently replaced by a Ford CSP 21N11. I made an appointment to have this issue addressed by a Ford dealership and they said that the CSP expired in 2022 and the vehicle is no longer covered despite the persistence of the safety issue and the fact that it has not been repaired for this known problem. With a significant issue, such as braking, I believe the expiration should be extended to allow for Ford owners to have this known safety issue addressed appropriately by Ford.
- Air bags · Service brakes, hydraulic
The contact owns a 2009 Ford Fusion. The contact stated while driving 35-45 MPH, the brake pedal was depressed; however, the vehicle was slow to respond. The check brakes system message was displayed. The ABS warning light was illuminated. The contact received notifications of NHTSA Campaign…
The contact owns a 2009 Ford Fusion. The contact stated while driving 35-45 MPH, the brake pedal was depressed; however, the vehicle was slow to respond. The check brakes system message was displayed. The ABS warning light was illuminated. The contact received notifications 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 local dealer was contacted. The dealer completed the air bag recall and diagnosed the vehicle and determined that the brake module and HECU module were corroded. The vehicle was not repaired. 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, but no additional assistance was provided. The failure mileage was approximately 96,970. Parts distribution disconnect.
- Service brakes
After activation of ABS brake system, brakes became "soft" and "spongy" with permanent increased braking time. As described in safety recall 19S54, this due to to a valve in the Hydraulic Control Unit (HCU) being stuck open. I received a letter from Ford Motor Company regarding this safety recall…
After activation of ABS brake system, brakes became "soft" and "spongy" with permanent increased braking time. As described in safety recall 19S54, this due to to a valve in the Hydraulic Control Unit (HCU) being stuck open. I received a letter from Ford Motor Company regarding this safety recall in 2011 informing of the defect and assuring "we will correct this condition." The vehicle was taken to Koons Ford (1051 E Broad St., Falls Church, VA, 22044; 703-241-7250) on 7/5/21 for repair. However, the HCU was not replaced, which appears to be the only remedy to this problem. Instead DOT 3 brake fluid was replaced with DOT 4 fluid, according to Koons Ford. However, after subsequent activation of the ABS brake system, the brakes became impaired again in the same way as before. I returned the car to Koons Ford on [XXX]. A "one-time" repair was performed pursuant to "customer satisfaction program" 21N11, as Ford acknowledged in a letter to dealers dated 12/7/21 that numerous customers were returning as the action prescribed in safety recall 19S54 did not repair the defective brakes. However, the HCU was not replaced. Service Advisor Kevin Lacki told me the HCU "passed" the inspection/diagnostic despite replication of the problem. I complained to Service Manager Rob Ryans who did nothing. I emailed the General Manager of the dealership twice, and he never responded. I called the manufacturer on [XXX] (case #[XXX]), but no action was taken. The problem of "soft" brakes and extended travel time quickly resurfaced and led to a vehicle accident in early 2023. The Ford Motor Company is employing a diagnostic that results in false "passes" for HCUs that should be replaced (and/or this dealership did not correctly perform the service actions). Even after "passing" Ford's diagnostic, the HCU valve(s) become stuck open after ABS activation. The safety recall should be investigated and the recall amended to replace faulty HCUs. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 55
- Service brakes
While i was driving and the car hits a hole if the road, and i tried to brake so i can controll the car the breakes became uresponsive for the moment and after a few seconds when i try to brake again the travel space of the brake pedal is increased a lot and is near the end, and it takes a lot before the things return to normal( so it happens only when the car try to activate te ABS system).
- Service brakes, hydraulic
The contact owns a 2009 Ford Fusion. The contact stated that while driving at various speeds, the brake pedal would depress to the floorboard without warning. The vehicle was taken to a dealer where the contact was informed that the Hydraulic Electric Control Unit (HECU) had failed and needed to be…
The contact owns a 2009 Ford Fusion. The contact stated that while driving at various speeds, the brake pedal would depress to the floorboard without warning. The vehicle was taken to a dealer where the contact was informed that the Hydraulic Electric Control Unit (HECU) had failed and needed to be replaced. Upon investigation, the contact discovered NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic). The manufacturer was notified of the failure and the contact was informed that the vehicle was not included in the recall. The vehicle was repaired. The failure mileage was 92,000.
- Service brakes
The contact owns a 2009 Ford Fusion. The contact stated that the vehicle was experiencing extended brake pedal travel while driving. The contact stated that while driving at various speeds and depressing the brake pedal, the brake pedal traveled down to the floorboard, causing the braking distance…
The contact owns a 2009 Ford Fusion. The contact stated that the vehicle was experiencing extended brake pedal travel while driving. The contact stated that while driving at various speeds and depressing the brake pedal, the brake pedal traveled down to the floorboard, causing the braking distance to be extended. There was no warning light illuminated. Additionally, the contact stated that while her husband was pulling into the garage, the brake pedal was depressed. Still, the failure recurred, causing the vehicle to crash into the garage wall. There was no injury sustained. The vehicle was drivable. The contact later received notification of Ford Campaign Number: 21N11. The vehicle was taken to the dealer, where the brake fluid and the brake fluid cap were replaced; however, the failure persisted. The contact stated that the dealer had not replaced the HCU. The dealer was notified of the failure. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 160,000.
- Electrical system › Wiring › Fuses and circuit breakers · Service brakes
The contact owns a 2009 Ford Fusion. The contact stated while driving at an undisclosed speed, the brake pedal depressed with no warning light illuminated. The vehicle was taken to the dealer however, the vehicle was not diagnosed or repaired. The contact was informed that the brake lines had been…
The contact owns a 2009 Ford Fusion. The contact stated while driving at an undisclosed speed, the brake pedal depressed with no warning light illuminated. The vehicle was taken to the dealer however, the vehicle was not diagnosed or repaired. The contact was informed that the brake lines had been flushed. The contact stated while driving at an undisclosed speed, the failure recurred. The vehicle was taken to the dealer for a second time, and the vehicle was diagnosed with an HECU fuse failure. The contact was informed that the HECU fuse needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance. The failure mileage was approximately 173,890.
- Steering · Suspension · Wheels
The potholes on the highway caused my tie rods and tires to explode!
- Service brakes
Chapman Ford in Marysville, Ohio has had my car for ABS recall for almost a month now. They said they are waiting on the HYDRAULIC CONTROL UNIT HCU. Is this normal to take this long to fix.
- Service brakes
Ford dealership refuses to replace ABS HCU unit. Recall states that it will be replaced if defective. Dealership said that it is defective but not part of the recall. Shows that it is part of the recall.
- Latches/locks/linkages › Doors › Latch
The contact owns a 2009 Ford Fusion. The contact stated that the front driver's side door became inoperable. The contact stated that the front driver's door failed to open. The contact stated that the door latch could be locked and unlocked; however, the front driver's door could not be opened. The…
The contact owns a 2009 Ford Fusion. The contact stated that the front driver's side door became inoperable. The contact stated that the front driver's door failed to open. The contact stated that the door latch could be locked and unlocked; however, the front driver's door could not be opened. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 100,000.
- Service brakes
Hcu fails and prolongs braking, brakes are often soft
- Engine and engine cooling › Exhaust system › Manifold/header/muffler/tail pipe
The contact owns a 2009 Ford Fusion. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic, who determined that the exhaust manifold valve was stuck in the open position. The vehicle was repaired…
The contact owns a 2009 Ford Fusion. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic, who determined that the exhaust manifold valve was stuck in the open position. The vehicle was repaired; however, the failure reoccurred. The vehicle was taken back to the independent mechanic, who determined that the exhaust manifold valve was stuck in the open position again. The vehicle was not repaired. The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was unknown.
- Service brakes
My brakes have been soft when I was sold the vehicle. I was assured multiple times that there is nothing wrong with them. As I have taken it in for multiple oil changes, the mechanics always seem to have a problem with the brakes. I’ve taken it to get the calipers, discs and master cylinder…
My brakes have been soft when I was sold the vehicle. I was assured multiple times that there is nothing wrong with them. As I have taken it in for multiple oil changes, the mechanics always seem to have a problem with the brakes. I’ve taken it to get the calipers, discs and master cylinder replaced and they have been bled for over 24 hours and are still soft and can’t find the reason. Every mechanic has told me they won’t pass safety yet I was sold this car with a safety pass. I’m still paying on this vehicle and haven’t even had it a year. The photos I uploaded are from Carfax Car care. I have receipts for the brakes and master cylinder being replaced if those are needed.
- Engine
Transmission will not go into gear. When it finally does shift it jumps completely forward or backwards depending on the gear. However, it does not matter which gear you put it in. It takes several attempts before it does go into gear; at that time it will completely jump forward/backward. This…
Transmission will not go into gear. When it finally does shift it jumps completely forward or backwards depending on the gear. However, it does not matter which gear you put it in. It takes several attempts before it does go into gear; at that time it will completely jump forward/backward. This causes great risk to myself and others on the road/parking lots. I never know when it is going to get in gear or if it will go out while driving. The problem has been reported to the Ford company. The vehicle as not been inspected by any manufacture or policy/insurance. There was no warning, or no warning when it happens.
- Tires
Tire size IS 205/60r16 upon driving vehicle tire developed rippling or buldging around entire sidewall
- Unknown or other
went to get my oil changed and tires rotated at the dealership they said they could not rotate tires because the lug nuts were swollen and they couldn't because they might break. this seems to be a common problem
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
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
- 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.
- 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.
- 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.
- 10056183Ford: the throttle body internal motor contacts may be contaminated, resulting in an electrical, intermittent, connectivity, causing malfunction indicator lamp (mil) or wrench light to be illuminated. Model 2009-2012 fusion, milan, escape, mariner. Updated 11/18/14.
- 10054926Ford: throttle body will develop contamination on internal motor contacts resulting in an intermittent electrical connectivity and malfunction indicator lamp (mil) or wrench light will illuminate. Model 2009-2013 fusion, milan, escape, mariner. Updated 5/7/14.
- 10039053Ford: if there IS an intermittent lack of power, surge, or hesitation while driving the brakes will override acceleration.
- 10038965Comm-trans lund: some 2009-2011 models may have the air bag inicator flashing with a stored trouble code. This IS a software problem.
- 10028506Ford/mercury: some vehicles may exhibit a malfunction indicator light (mil) on with diagnostic trouble codes (dtcs) p0340 and/or p0344 (camshaft position sensor circuit). May be due to incorrect reading from the camshaft sensor.
Every Ford Fusion model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.