What is the 2013-2016 Ford Fusion Door Latch Pawl Spring Failure - Door Opens While Driving?

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… Repairs typically run $0-$0. Severity: high.

What is the 2014-2019 Ford Fusion 1.5L EcoBoost Coolant Intrusion into Cylinders - Internal Engine Block Failure?

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 maintai… Repairs typically run $0-$7,000. 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.

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 2013-2018 Ford Fusion Front Brake Hose Rupture - Loss of Brake Fluid and Longer Stopping (Recall 23S12)?

A design flaw in the front brake hoses lets them rupture over time, leaking brake fluid and increasing stopping distance. Ford recalled roughly 1.2-1.28 million Fusion and Lincoln MKZ sedans (recall 23S12) in 2023 after an NHTSA investigation. A ruptured hose causes a low brake-f… Repairs typically run $0-$400. Severity: high.

What is the 2013-2016 Ford Fusion Shifter Cable Bushing Detaches - Vehicle Rollaway Risk (Recall 18S20 / 22S43)?

A plastic bushing that attaches the shift cable to the transmission can degrade and pop off, so the transmission may be in a different gear than the shift lever indicates. The driver can shift to Park, remove the key, and walk away while the transmission is actually not in Park,… Repairs typically run $0-$300. Severity: high.

What is the 2013-2016 Ford Fusion MyFord Touch / SYNC 2 (APIM) Freezing, Black Screen, and Rebooting?

The MyFord Touch / SYNC 2 system (driven by the APIM module) is widely reported to freeze, go black, reboot repeatedly, lose Bluetooth pairing, and drop audio or backup-camera display. The Accessory Protocol Interface Module (APIM) has a known tendency to fail, and Ford extended… Repairs typically run $200-$900. Severity: medium.

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 2013-2016 Ford Fusion Power Window Regulator Failure and Window Bounce-Back?

Gen-2 Fusions have a long-running window-module/regulator problem. A common 'bounce-back' fault makes the window roll up, hit the top, and immediately drop back down, and worn regulator gears/cables cause clicking, chattering, or grinding and can drop the glass inside the door. T… Repairs typically run $150-$450. Severity: medium.

What is the 2013-2018 Ford Fusion Water Intrusion into Trunk/Tire Well - Wet Carpet and Corroded Modules?

Fusion owners frequently find water pooling in the trunk/spare-tire well and wet rear carpet. Sources include leaking taillight gaskets/plastic rivet pass-throughs, deteriorated trunk and rear-window seals, and split spot-welds in the channel under the rear glass. Standing water… Repairs typically run $50-$600. Severity: medium.

Ford · Known Issues

2016 Ford Fusion Problems: 15 Known Issues

2016 model year · 7,610+ owner reports · Updated September 2026

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According to Au7o's analysis of 7,610+ owner reports, the 2016 Ford Fusion has 15 documented known issues, with 10 rated critical. The most serious are Electric Power Steering (EPS) Failure - Sudden Loss of Assist ($0-$2,800 repair), Door Latch Pawl Spring Failure - Door Opens While Driving ($0-$0 repair), 1.5L EcoBoost Coolant Intrusion into Cylinders - Internal Engine Block Failure ($0-$7,000 repair), Hybrid High-Voltage Battery Degradation and Failure ($1,500-$7,000 repair), Corroded Electric Power Steering Gear Motor Bolts - Loss of Steering Assist (Recall 19V632 / Ford 19S26), 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), Electronic Throttle Body Failure - Limp Mode and Wrench Light ($250-$550 repair), .

Frequently Asked Questions

What are the most common Ford Fusion problems?

According to Au7o's analysis of 7,610+ owner reports, the 2016 Ford Fusion has 15 documented issues. The most frequently reported are: Electric Power Steering (EPS) Failure - Sudden Loss of Assist, Door Latch Pawl Spring Failure - Door Opens While Driving, 1.5L EcoBoost Coolant Intrusion into Cylinders - Internal Engine Block Failure. Of these, 10 are rated critical and should be addressed promptly.

Is the Ford Fusion reliable?

The 2016 Ford Fusion has 15 known issues documented across 7,610+ owner reports. 10 issues are rated critical: Electric Power Steering (EPS) Failure - Sudden Loss of Assist and Door Latch Pawl Spring Failure - Door Opens While Driving and 1.5L EcoBoost Coolant Intrusion into Cylinders - Internal Engine Block Failure and Hybrid High-Voltage Battery Degradation and Failure and Corroded Electric Power Steering Gear Motor Bolts - Loss of Steering Assist (Recall 19V632 / Ford 19S26) 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 and Front Brake Hose Rupture - Loss of Brake Fluid and Longer Stopping (Recall 23S12) and Shifter Cable Bushing Detaches - Vehicle Rollaway Risk (Recall 18S20 / 22S43). 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 $0 to $7,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Electric Power Steering (EPS) Failure - Sudden Loss of Assist, typically costs $0-$2,800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2013-2018 Ford Fusion Electric Power Steering (EPS) Failure - Sudden Loss of Assist?

2014-2018 Ford Fusions use a different EPS module revision than the 2011-2013 recall (NHTSA 15V340) — but owners still report sudden loss of power steering assist, particularly at higher mileage. Without recall coverage, repairs are owner-paid: rack replacement typically $1,200-$… Repairs typically run $0-$2,800. Severity: high.

All 15 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 2013-2018 Ford Fusion Electric Power Steering (EPS) Failure - Sudden Loss of Assist?

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

2013-2016 Ford Fusion: Shifter Cable Bushing Detaches - Vehicle Rollaway Risk (Recall 18S20 / 22S43)#

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

2013-2016 Ford Fusion: MyFord Touch / SYNC 2 (APIM) Freezing, Black Screen, and Rebooting#

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

2013-2018 Ford Fusion: Electric Power Steering (EPS) Failure - Sudden Loss of Assist#

2013-2016 Ford Fusion: Door Latch Pawl Spring Failure - Door Opens While Driving#

2014-2019 Ford Fusion: 1.5L EcoBoost Coolant Intrusion into Cylinders - Internal Engine Block Failure#

2013-2016 Ford Fusion: Corroded Electric Power Steering Gear Motor Bolts - Loss of Steering Assist (Recall 19V632 / Ford 19S26)#

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#

2013-2018 Ford Fusion: Front Brake Hose Rupture - Loss of Brake Fluid and Longer Stopping (Recall 23S12)#

2013-2016 Ford Fusion: Power Window Regulator Failure and Window Bounce-Back#

2013-2018 Ford Fusion: Water Intrusion into Trunk/Tire Well - Wet Carpet and Corroded Modules#

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