According to Au7o's analysis of 4,200+ owner reports, the 2020 Ford Fusion has 2 documented known issues, with 2 rated critical. The most serious are Electric Power Steering Rack and Gear Failure ($1,200-$3,500 repair) and Hybrid High-Voltage Battery Degradation and Failure ($1,500-$7,000 repair). The most commonly reported issue is Electric Power Steering Rack and Gear Failure with 2,800 owner reports. Across all issues, repair costs range from $1,200 to $7,000. DIY maintenance guides at au7o.io.
On the 2010-2020 Ford Fusion, 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.
Complete loss of power steering (requires significant force to turn)
Steering assist comes and goes unpredictably
Check engine light or power steering fault code stored
How to Fix
Check if your vehicle is covered under Ford recall (2011-2012 Fusion/MKZ power steering failure recall - free repair). For non-recall vehicles, the electric power steering rack must be replaced as a complete unit since the motor and control electronics are integrated. RepairPal estimates $1,958-3,362 installed. Remanufactured racks from PWR Steer or Cardone are available at $800-1,500, significantly cheaper than new OEM ($2,000+). Have the alignment performed after rack replacement.
What Owners Are Using
Parts and tips from 2,800+ owners who fixed this issue
NoteIf your Fusion suddenly loses power steering assist, you can still steer the car but it requires significant effort. Pull over safely and do not drive at highway speeds without power assist. Complete loss of EPAS is a safety hazard, especially in emergency maneuvers.
TipRemanufactured electric steering racks from PWR Steer or Cardone are $800-1,500 vs $2,000+ for new OEM. Independent shops can install them for $400-600 labor. This can save $1,000+ over dealer pricing. Always get an alignment after rack replacement.
UpgradeInner and outer tie rod ends for steering precision restoration (Moog Tie Rod End)
Medium Confidence2,800 reportsLast reported by owners Feb 2026Reviewed Feb 2026
Community Reported
1,400 owners
On the 2010-2020 Ford Fusion, 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.
Hybrid system shuts down and runs on gasoline only
How to Fix
Check warranty first - Ford covers 8yr/100k miles (10yr/150k in CA, CT, MA, ME, MD, NJ, NY, OR, PA, RI, VT, WA states). If out of warranty, aftermarket/remanufactured battery packs from GreenTecAuto ($1,550-2,950 installed) are significantly cheaper than dealer replacement ($4,000-7,000). Individual cell replacement at specialized hybrid shops ($800-2,000) is an option if only specific cells have failed. Battery reconditioning is a temporary fix that may restore 60-80% of capacity for $300-800.
What Owners Are Using
Parts and tips from 1,400+ owners who fixed this issue
TipGreenTecAuto and BestHybridBatteries offer remanufactured Fusion Hybrid battery packs at $1,550-2,950, roughly half the dealer cost. These come with 3-5 year warranties. They also offer mobile installation in many areas.
NoteFord hybrid battery warranty is 8yr/100k (10yr/150k in CARB states). Check your state emissions warranty laws - you may have more coverage than you think. A "Check Hybrid System" warning within the warranty period should be a no-cost dealer repair.
UpgradeHigh-performance AGM battery with excellent cold cranking amps and deep cycle capability (Optima RedTop AGM Battery)
Medium Confidence1,400 reportsLast reported by owners Feb 2026Reviewed Feb 2026
⚠️NHTSA Recalls17 recalls
ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM)
Ford Motor Company (Ford) is recalling certain 2019-2020 Fusion PHEV vehicles. The battery energy control module (BECM) may become damaged due to excessive voltage and current flow.
Campaign #23V44000013/09/2023
BACK OVER PREVENTION:SOFTWARE
Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2024 Bronco Sport, and 2022-2024 Maverick vehicles. A software error may cause the rearview camera to display a blank image, or the image may remain on the display after the backing event has ended.
Campaign #25V44200027/06/2025
EQUIPMENT:ELECTRICAL:ENGINE BLOCK HEATER
Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles. The engine block heater may crack and develop a coolant leak, causing it to short circuit when the block heater is plugged in.
Campaign #25V68500010/10/2025
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS
Ford Motor Company (Ford) is recalling certain 2013-2018 Fusion and Lincoln MKZ vehicles. The front brake hoses may rupture and leak brake fluid.
Campaign #23V16200010/03/2023
STEERING: STEERING WHEEL/HANDLE BAR
Ford Motor Company (Ford) is recalling certain 2014-2018 Lincoln MKZ and Ford Fusion vehicles. The steering wheel retaining bolt may loosen allowing the steering wheel to detach while driving.
According to Au7o's analysis of 4,200+ owner reports, the 2020-2020 Ford Fusion has 2 documented issues. The most frequently reported are: Electric Power Steering Rack and Gear Failure, Hybrid High-Voltage Battery Degradation and Failure. Of these, 2 are rated critical and should be addressed promptly.
Is the Ford Fusion reliable?
The 2020-2020 Ford Fusion has 2 known issues documented across 4,200+ owner reports. 2 issues are rated critical: Electric Power Steering Rack and Gear Failure and Hybrid High-Voltage Battery Degradation and Failure. 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 $1,200 to $7,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Electric Power Steering Rack and Gear Failure, 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 2010-2020 Ford Fusion Electric Power Steering Rack and Gear Failure?
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 F… Repairs typically run $1,200-$3,500. Severity: high.
What is the 2010-2020 Ford Fusion Hybrid High-Voltage Battery Degradation and Failure?
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… Repairs typically run $1,500-$7,000. Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
