2016 Ford Fusion Problems: 15 Known Issues

On the 2013-2016 Ford Fusion, 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, allowing the car to roll away. Ford issued recall 18S20 in 2018 (~504,000 vehicles) and later expanded it as 22V413/22S43 after the first repair proved inadequate, adding a protective cap.

On the 2010-2019 Ford Fusion, 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 longer hold clean line pressure, clogged/worn shift solenoids, and torque-converter clutch degradation. Many units develop symptoms well before 100,000 miles. A 2021 class-action lawsuit (Gant v. Ford) accused Ford of concealing the 6F35 defect on the Fusion.

On the 2010-2020 Ford Fusion, 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 $2,500-$4,000 at independent hybrid specialists. 2nd-gen 2013-2020 (Lithium-ion, ~1.4 kWh): better thermal management has led to longer life on average but cell imbalance issues appear at 150,000+ miles. 'Stop Safely Now' warnings often precede full failure. 2013-2020 Energi PHEV variants share the architecture but with larger 7.6 kWh batteries — separate degradation curve. Owners should check cell balance via OBD-II scanner with hybrid module support (Forscan recommended).

On the 2010-2018 Ford Fusion, 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. A healthy vehicle should draw under ~50mA at rest; failed modules keep the network awake and flatten the battery.

On the 2013-2016 Ford Fusion, 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 warranty coverage on the module for affected owners. Beyond annoyance, a blank screen can disable the backup camera and climate controls.

On the 2013-2018 Ford Fusion, 2013-2018 Ford Fusions use a different EPS system than the 2011-2012 Fusion covered by 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-$2,000. Symptoms mirror the recalled generation (heavy steering, intermittent warnings, eventual full assist loss). For 2013-2016 Fusions originally sold or registered in salt-belt states, recalls 15V250 (Ford 15S14) and 19V632 (Ford 19S26) cover corrosion of the EPS gear motor attachment bolts.

On the 2013-2016 Ford Fusion, 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 15V246 (Ford 15S16), expanded with 17V210, then 20V177 and 23V775 (Ford 20S15) for 2014-2016 Fusions in hot/humid states, plus 20V331 (Ford 20S30) for latches that may have been improperly repaired. Ford and Lincoln recalled over 2 million vehicles total across multiple model lines for this defect.

On the 2014-2019 Ford Fusion 1.5L EcoBoost, 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 TSBs 19-2139, 19-2375 and 20-2100 direct short block and head gasket replacement on 2014-2019 Fusion 1.5L vehicles, and Ford Customer Satisfaction Program 21N12 provides extended coverage for the short block replacement on certain 2017-2019 Fusion 1.5L vehicles. 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.

On the 2010-2019 Ford Fusion, 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 smell in the cabin, whining/growling, and eventually PTU seizure that can damage the transmission. Failures often occur relatively early in the car's life.

On the 2013-2016 Ford Fusion, ford recalled 2013-2016 Fusion sedans registered or originally sold in road-salt states because the bolts holding the electric power steering gear motor to the steering gear housing can corrode. Road salt and other winter road contaminants attack the attachment bolts, and if they corrode enough to break, the steering gear motor can detach from the housing. The Fusion then loses power steering assist, so the car takes noticeably greater effort to steer, especially at low speeds such as parking or turning into a driveway, which raises the risk of a crash. The salt-belt states named by NHTSA are Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin. The recall covers 116,160 vehicles campaign-wide across all of the models included, not the Fusion alone.

On the 2010-2016 Ford Fusion, 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, or stalling, sometimes in traffic. Ford acknowledged the problem with extended-warranty program 13N03 for 2010-2013 models and Customer Satisfaction Program 16B32 for certain 2015-2016 vehicles including Fusion.

On the 2013-2018 Ford Fusion, 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-fluid warning, a change in pedal feel, and a real crash risk from degraded braking.

On the 2013-2018 Ford Fusion, 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 risks rust and corrosion of trunk-mounted electronics (on hybrids the high-voltage battery and electronics sit in this area), plus musty odor and mold.

On the 2013-2016 Ford Fusion, 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. The driver-door switch and window-module re-initialization are frequently involved. Documented across 2013-2016 and beyond.

On the 2006-2020 Ford Fusion, 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 temperature, wrong vent output, or one side blowing hot while the other blows cold. It is one of the most common Fusion comfort complaints across all generations.