What is the 2010-2019 Ford Fusion 6F35 6-Speed Automatic Harsh/Delayed Shifting and Torque Converter Shudder?

The 6F35 six-speed automatic is prone to harsh, banging, or delayed shifts (most often 2-3 and 3-4) plus a shudder/vibration when the torque converter clutch locks up at a steady 40-60 mph cruise. Root causes are worn valve-body separator-plate O-rings and bores that can no longe… Repairs typically run $250-$3,500. Severity: high.

What is the 2010-2019 Ford Fusion AWD Power Transfer Unit (PTU) Overheating and Fluid Leak Failure?

On AWD Fusions the Power Transfer Unit holds only about a quart of gear oil with no dipstick, service interval, or cooling, sitting next to hot exhaust and transaxle. The fluid cooks and breaks down, becoming thick, gummy, and black, and the seals leak. Owners report a burning sm… Repairs typically run $400-$3,100. Severity: high.

What is the 2010-2016 Ford Fusion Electronic Throttle Body Failure - Limp Mode and Wrench Light?

The electronic throttle body suffers internal contamination/wear of the motor contacts, causing intermittent electrical failure rather than simple dirt buildup. The result is a sudden loss of power (limp/failsafe mode) with the amber wrench (powertrain) warning light, rough idle,… Repairs typically run $250-$550. Severity: high.

What is the 2006-2020 Ford Fusion HVAC Blend Door Actuator Failure - Clicking/Knocking Behind Dash, No Heat or AC?

The plastic gears inside the HVAC blend-door actuator strip out, so the door can no longer move to route air correctly. The classic symptom is a repeated clicking or knocking noise from behind the dash (often at startup or when changing temperature), along with air stuck on one t… Repairs typically run $156-$400. Severity: medium.

What is the 2010-2018 Ford Fusion Parasitic Battery Drain - Dead Battery / No Start (BCM & Modules)?

Many Fusion owners report the battery going dead overnight or over a weekend from a parasitic draw. Common culprits are a module that fails to sleep - Body Control Module (BCM), APIM/infotainment, or amplifier - as well as the PATS anti-theft transceiver circuit on earlier cars. Repairs typically run $150-$1,000. Severity: medium.

What is the 2010-2012 Ford Fusion EVAP Purge Valve Stuck/Leaking - Check Engine Light and Rough Running?

The under-hood evaporative-emissions purge valve on 2010-2011 Fusion/Milan (2.5L DOHC and 3.0L) built on or before 3/4/2011 can stick open or leak, unmetered vapor entering the intake. This lights the MIL and sets a cluster of EVAP and lean/fuel-trim codes, and can cause rough id… Repairs typically run $100-$300. Severity: low.

Ford · Known Issues

2012 Ford Fusion Problems: 8 Known Issues

2012 model year · 4,200+ owner reports · Updated September 2026

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According to Au7o's analysis of 4,200+ owner reports, the 2012 Ford Fusion has 8 documented known issues, with 5 rated critical. The most serious are Electric Power Steering Rack Failure (Recall 15V340) ($1,200-$3,500 repair), Hybrid High-Voltage Battery Degradation and Failure ($1,500-$7,000 repair), 6F35 6-Speed Automatic Harsh/Delayed Shifting and Torque Converter Shudder ($250-$3,500 repair), AWD Power Transfer Unit (PTU) Overheating and Fluid Leak Failure ($400-$3,100 repair) and Electronic Throttle Body Failure - Limp Mode and Wrench Light ($250-$550 repair). The most commonly reported issue is Electric Power Steering Rack Failure (Recall 15V340) with 2,800 owner reports. Across all issues with published estimates, repair costs range from $100 to $7,000. DIY maintenance guides at au7o.io.

Frequently Asked Questions

What are the most common Ford Fusion problems?

According to Au7o's analysis of 4,200+ owner reports, the 2012 Ford Fusion has 8 documented issues. The most frequently reported are: Electric Power Steering Rack Failure (Recall 15V340), Hybrid High-Voltage Battery Degradation and Failure, 6F35 6-Speed Automatic Harsh/Delayed Shifting and Torque Converter Shudder. Of these, 5 are rated critical and should be addressed promptly.

Is the Ford Fusion reliable?

The 2012 Ford Fusion has 8 known issues documented across 4,200+ owner reports. 5 issues are rated critical: Electric Power Steering Rack Failure (Recall 15V340) and Hybrid High-Voltage Battery Degradation and Failure and 6F35 6-Speed Automatic Harsh/Delayed Shifting and Torque Converter Shudder and AWD Power Transfer Unit (PTU) Overheating and Fluid Leak Failure and Electronic Throttle Body Failure - Limp Mode and Wrench Light. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Ford Fusion problems?

Repair costs for known Ford Fusion issues range from $100 to $7,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Electric Power Steering Rack Failure (Recall 15V340), typically costs $1,200-$3,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2011-2013 Ford Fusion Electric Power Steering Rack Failure (Recall 15V340)?

NHTSA recall 15V340 covers 2011-2013 Ford Fusion (and Lincoln MKZ) without the 3.5L engine. An intermittent electrical connection in the steering gear can cause sudden loss of electric power steering assist while driving. Owners notice heavier steering effort especially at low sp… Repairs typically run $1,200-$3,500. Severity: high.

What is the 2010-2020 Ford Fusion Hybrid High-Voltage Battery Degradation and Failure?

Ford Fusion Hybrid spans two generations with different high-voltage batteries — degradation patterns differ. 1st-gen 2010-2012 (NiMH, ~1.4 kWh): typical degradation appears at 100,000-150,000 miles with reduced EV-mode range and increased ICE intervention. Replacement runs $2,50… Repairs typically run $1,500-$7,000. Severity: high.

All 8 Known Issues

Other Ford Models

Frequently Asked Questions

What are the most common Ford Fusion problems?

Is the Ford Fusion reliable?

How much does it cost to fix common Ford Fusion problems?

What is the 2011-2013 Ford Fusion Electric Power Steering Rack Failure (Recall 15V340)?

What is the 2010-2020 Ford Fusion Hybrid High-Voltage Battery Degradation and Failure?

2010-2020 Ford Fusion: Hybrid High-Voltage Battery Degradation and Failure#

2010-2018 Ford Fusion: Parasitic Battery Drain - Dead Battery / No Start (BCM & Modules)#

2011-2013 Ford Fusion: Electric Power Steering Rack Failure (Recall 15V340)#

2010-2019 Ford Fusion: 6F35 6-Speed Automatic Harsh/Delayed Shifting and Torque Converter Shudder#

2010-2019 Ford Fusion: AWD Power Transfer Unit (PTU) Overheating and Fluid Leak Failure#

2010-2016 Ford Fusion: Electronic Throttle Body Failure - Limp Mode and Wrench Light#

2006-2020 Ford Fusion: HVAC Blend Door Actuator Failure - Clicking/Knocking Behind Dash, No Heat or AC#

2010-2012 Ford Fusion: EVAP Purge Valve Stuck/Leaking - Check Engine Light and Rough Running#