Ford Fusion Problems: 5 Issues Every Owner Should Know

The 2010-2020 Ford Fusion with electric power steering (EPAS) experiences steering rack and gear assembly failures, including internal motor failure, torque sensor faults, and complete loss of power assist. A class action lawsuit was filed over power steering issues in the Ford Focus and Fusion. Ford issued a recall for 2011-2012 Fusion and Lincoln MKZ models for power-assisted steering failure. RepairPal estimates rack and pinion replacement between $1,958 and $3,362 depending on model year, making this one of the most expensive common repairs on the Fusion. The electric motor and electronic control unit integrated into the steering rack are the primary failure points. BuyAutoParts.com documents the high replacement cost of the integrated electric steering rack assembly. Symptoms range from intermittent loss of assist to complete steering failure requiring significant physical force to turn the wheel.

The electric power steering system in 2013-2018 Ford Fusion is prone to sudden failure, leaving drivers with manual (heavy) steering with no power assist. Multiple separate issues cause this: (1) EPS motor sensor fault causing immediate shutdown (Recall 15V340 / 15S18 for 2011-2013 models), (2) corrosion of EPS gear motor attachment bolts from road salt/water contamination causing the steering motor to detach from the housing (Recall 19V632 for 2013-2015 Fusion/MKZ), and (3) general EPS control module failures. NHTSA investigated Ford Fusion power steering failures for 7 years before ultimately closing the investigation without additional recalls. Hundreds of NHTSA complaints document sudden loss of steering assist at highway speeds.

The 2013-2016 Ford Fusion is subject to multiple door latch recalls due to the pawl spring tab inside the side door latches fracturing. The design is susceptible to failure in high-temperature and high-humidity climates. Over 90% of warranty claims occurred in hot/humid states. A fractured pawl spring tab causes the door to fail to latch properly, or to open unexpectedly while the vehicle is moving. Ford issued multiple recalls covering Fusion: the original 14S17, expanded with 16V643, and additional recalls covering 2014-2016 Fusion specifically. Ford and Lincoln recalled over 2 million vehicles total across multiple model lines for this defect.

The 1.5L EcoBoost in 2014-2019 Ford Fusion is affected by the same open-deck cylinder block design defect as the Escape. Coolant leaks internally from the block passages into the combustion chambers due to insufficient sealing surface and porous block material that cannot maintain coolant pressure over time. Ford extended warranty coverage to 7 years/84,000 miles for short block replacement per TSB 19-2139 and TSB 19-2375. A consolidated class action lawsuit covers 2013-2019 Fusion and Escape with 1.5L, 1.6L, and 2.0L EcoBoost engines. Some owners have experienced engine failure with no warning - no check engine light before coolant hydrolocked the cylinder.

The 2010-2020 Ford Fusion Hybrid and Fusion Energi plug-in hybrid experience high-voltage battery degradation over time, resulting in reduced electric-only range, decreased fuel efficiency, and eventual battery failure. FIXD App and GreenTecAuto document battery replacement costs ranging from $1,550 to $7,000 depending on the source of the replacement battery and model year. Symptoms include reduced EV range, "Check Hybrid System" dashboard warning, sluggish acceleration, and in severe cases inability to start the vehicle. Ford provides an 8-year/100,000-mile warranty on the hybrid battery (10yr/150k in CARB states), but many batteries degrade before complete failure, leaving owners with poor fuel economy but no warranty claim. The 2010-2012 Fusion Hybrid uses a Ni-MH battery while 2013+ models use lithium-ion, with different degradation patterns.