Ford · Known Issues
2010 Ford Fusion Problems: 8 Known Issues
2010 model year · 1,400+ owner reports · Updated September 2026
2010 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
2010 model year · 1,400+ owner reports · Updated September 2026
2010 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
Interest applies to the selected vehicle and configuration; it is not a reservation. Voting stores a first-party identifier for up to 180 days to prevent repeat votes. No account or email is needed. Clearing cookies or using another device may count separately. Privacy
Visual coming soon
Your interest helps us choose what to build next.
Visual Known Issues · Coming soon
$4.99/month plus taxes at launch · No payment today
According to Au7o's analysis of 1,400+ owner reports, the 2010 Ford Fusion has 8 documented known issues, with 5 rated critical. The most serious are Hybrid High-Voltage Battery Degradation and Failure ($1,500-$7,000 repair), 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) and 6F35 6-Speed Automatic Harsh/Delayed Shifting and Torque Converter Shudder ($250-$3,500 repair). The most commonly reported issue is Hybrid High-Voltage Battery Degradation and Failure with 1,400 owner reports. Across all issues with published estimates, repair costs range from $100 to $7,000. DIY maintenance guides at au7o.io.
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.
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.
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.
POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER
Ford Motor Company (Ford) is recalling certain 2017 Lincoln MKZ and Ford Edge and Fusion vehicles. On vehicles with 2.0L gas engines and six-speed automatic transmissions, the torque converter weld studs may have been inadequately welded.
SEATS:MID/REAR ASSEMBLY
Ford Motor Company (Ford) is recalling certain 2017 Ford Fusion vehicles manufactured September 27, 2016, to September 28, 2016. The left rear seat backs pivot pins may have been improperly welded.
+ 13 more recalls. Check all on NHTSA.gov
Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.
Don't see your problem? Describe your symptoms to get a diagnosis, or get a full repair guide.
According to Au7o's analysis of 1,400+ owner reports, the 2010 Ford Fusion has 8 documented issues. The most frequently reported are: Hybrid High-Voltage Battery Degradation and Failure, ABS Hydraulic Control Unit Valves Stick Open - Long Brake Pedal Travel (Recall 19V904 / Ford 19S54), Electronic Throttle Body Failure - Limp Mode and Wrench Light. Of these, 5 are rated critical and should be addressed promptly.
The 2010 Ford Fusion has 8 known issues documented across 1,400+ owner reports. 5 issues are rated critical: Hybrid High-Voltage Battery Degradation and Failure 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 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 $100 to $7,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Hybrid High-Voltage Battery Degradation and Failure, typically costs $1,500-$7,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
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 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.
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 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.
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.