Ford · Known Issues
2006-2020 Ford Fusion Problems: 20 Known Issues
2006-2020 model years · 10,410+ owner reports · Updated September 2026
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2006-2020 model years · 10,410+ owner reports · Updated September 2026
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According to Au7o's analysis of 10,410+ owner reports, the 2006-2020 Ford Fusion has 20 documented known issues, with 14 rated critical. The most serious are Electric Power Steering Rack Failure (Recall 15V340) ($1,200-$3,500 repair), 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), ABS Hydraulic Control Unit Valves Stick Open - Long Brake Pedal Travel (Recall 19V904 / Ford 19S54), Electronic Throttle Body Failure - Limp Mode and Wrench Light ($250-$550 repair), AWD Power Transfer Unit (PTU) Overheating and Fluid Leak Failure ($400-$3,100 repair), Front Brake Hose Rupture - Loss of Brake Fluid and Longer Stopping (Recall 23S12) ($0-$400 repair), Shifter Cable Bushing Detaches - Vehicle Rollaway Risk (Recall 18S20 / 22S43) ($0-$300 repair), 1.6L EcoBoost Localized Cylinder-Head Overheating and Engine Fire (Recall 14V437) ($0-$6,000 repair), Fusion Backup Camera Displays a Blank Image or Fails to Clear (Recall 25S72 / NHTSA 25V442) and 6F35 6-Speed Automatic Harsh/Delayed Shifting and Torque Converter Shudder ($250-$3,500 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 $50 to $7,000. DIY maintenance guides at au7o.io.
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.
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.
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.
STEERING:ELECTRIC POWER ASSIST SYSTEM
Ford Motor Company (Ford) is recalling certain 2013-2016 Ford Fusion and Lincoln MKZ, 2015-2016 Ford Edge, and 2016 Lincoln MKX vehicles originally sold, or currently registered in 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. Road salt or other contaminants may corrode the electric power steering gear motor attachment bolts.
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:FLOOR SHIFT
Ford Motor Company (Ford) is recalling certain 2013-2014 Ford Escape, and 2013-2016 Ford Fusion vehicles, equipped with six-speed automatic transmissions. The bushing that attaches the transmission shifter cable to the transmission may degrade over time and cause the bushing to detach from the transmission. The condition could allow the driver to move the shift lever to Park and remove the ignition key, while the transmission may not be in Park, with no warning message or audible chime.
+ 13 more recalls. Check all on NHTSA.gov
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According to Au7o's analysis of 10,410+ owner reports, the 2006-2020 Ford Fusion has 20 documented issues. The most frequently reported are: Electric Power Steering Rack Failure (Recall 15V340), Electric Power Steering (EPS) Failure - Sudden Loss of Assist, Door Latch Pawl Spring Failure - Door Opens While Driving. Of these, 14 are rated critical and should be addressed promptly.
The 2006-2020 Ford Fusion has 20 known issues documented across 10,410+ owner reports. 14 issues are rated critical: Electric Power Steering Rack Failure (Recall 15V340) and 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 ABS Hydraulic Control Unit Valves Stick Open - Long Brake Pedal Travel (Recall 19V904 / Ford 19S54) and Electronic Throttle Body Failure - Limp Mode and Wrench Light and AWD Power Transfer Unit (PTU) Overheating and Fluid Leak Failure 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) and 1.6L EcoBoost Localized Cylinder-Head Overheating and Engine Fire (Recall 14V437) and Fusion Backup Camera Displays a Blank Image or Fails to Clear (Recall 25S72 / NHTSA 25V442) and 6F35 6-Speed Automatic Harsh/Delayed Shifting and Torque Converter Shudder. 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.
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 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.
Reliability varies across model years of the Ford Fusion. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 2006-2020 Ford Fusion with 20 documented issues documented across 10,410+ owner reports.
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.
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.
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.
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.
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.
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… Severity: high.
Ford recalled 2006-2010 Fusion sedans because valves inside the ABS Hydraulic Control Unit (HCU) can react with brake fluids that contain certain corrosion-preventative additives. That reaction can leave a valve from closing properly. In a Fusion with a stuck valve, the driver ma… Severity: high.
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.
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.
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.
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.
Early 1.6L EcoBoost Fusions can suffer a localized lack of coolant circulation that overheats one corner of the cylinder head; the head cracks and pushes oil/coolant onto the hot exhaust, and vehicle fires occurred while driving or after shutdown. Ford recall 14V437 covers 2013 F… Repairs typically run $0-$6,000. Severity: high.
The 2019 and 2020 Ford Fusion is one of the vehicles named in NHTSA recall 25V442000, Ford's campaign 25S72. A software error in the rearview camera system can cause the camera to display a blank image when the car is placed in reverse, or leave the reversing image on the display… Severity: high.
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.
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.
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.
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.
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.
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.
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.
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.