Ford · Known Issues
2016 Ford Fusion Problems: 15 Known Issues
2016 model year · 7,610+ owner reports · Updated September 2026
2016 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
2016 model year · 7,610+ owner reports · Updated September 2026
2016 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
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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), 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) 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 (EPS) Failure - Sudden Loss of Assist with 2,340 owner reports. Across all issues with published estimates, repair costs range from $50 to $7,000. DIY maintenance guides at au7o.io.
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.
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:FLOOR SHIFT
Ford Motor Company (Ford) is recalling certain 2013-2016 Fusion vehicles equipped with 2.5 liter engines. 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.
POWER TRAIN:MANUAL TRANSMISSION
Ford Motor Company (Ford) is recalling certain 2015-2018 Focus and 2013-2016 Fusion vehicles previously repaired incorrectly under recall numbers 18V169 and 18V845. The clutch may fracture, resulting in damage to the transmission assembly and possibly a transmission fluid leak.
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.
+ 13 more recalls. Check all on NHTSA.gov
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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.
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 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 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 (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.
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.
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.
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.
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.