2016 Ford Fusion Problems: 4 Issues Every Owner Should Know

2016 model year · 7,610+ owner reports · Updated May 2026

According to Au7o's analysis of 7,610+ owner reports, the 2016 Ford Fusion has 4 documented known issues, with 4 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) and Hybrid High-Voltage Battery Degradation and Failure ($1,500-$7,000 repair). The most commonly reported issue is Electric Power Steering (EPS) Failure - Sudden Loss of Assist with 2,340 owner reports. Across all issues, repair costs range from $1,500 to $7,000. DIY maintenance guides at au7o.io.

All 4 Known Issues

Community Reported

2,340 owners

On the 2013-2018 Ford Fusion, 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-$2,000. Symptoms mirror the recalled generation (heavy steering, intermittent warnings, eventual full assist loss). For 2013 specifically, the 15V340 recall applies if the vehicle is without the 3.5L engine.

This issue also affects: Chevrolet Camaro, Chevrolet Equinox, Ford Edge

Common Symptoms

"Service Power Steering" warning message on instrument cluster
Sudden heavy steering requiring much more effort, especially at low speeds
Steering wheel becomes very difficult to turn
"Hill Assist Not Available" and "Service AdvanceTrac" warnings accompanying EPS failure
Intermittent loss of power steering that returns after restart
Complete steering assist loss at any speed
Grinding or clicking from steering column during turns

How to Fix

Check safercar.gov with VIN for Recall 15V340/15S18 and 19V632 eligibility - free dealer repair. Out-of-recall: EPS rack assembly replacement ($1,200-$2,800). If experiencing intermittent "Service Power Steering" warning: try restarting vehicle as temporary workaround (does not fix underlying issue). Avoid car washes with high-pressure undercarriage spray aimed at steering gear area (accelerates bolt corrosion on 2013-2015 models).

What Owners Are Using

Parts and tips from 2,340+ owners who fixed this issue

NoteCheck safercar.gov NOW for recalls 15V340 and 19V632 - both provide free EPS repair. Recall 19V632 specifically covers corrosion of EPS motor bolts that can cause the motor to DETACH from the steering gear - a catastrophic failure at any speed.
NoteIf "Service Power Steering" appears, immediately slow down safely - steering effort is now entirely manual. Turning will require 3-4x normal effort. Do not attempt U-turns or parking lot maneuvers without extra caution. This is a safety-critical failure.
TipThe "temporary fix" of restarting the car when EPS fails is documented - this can reset the fault and restore power steering temporarily. But this is a band-aid: the underlying EPS hardware must be inspected and repaired. Do not rely on the restart trick permanently.
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Typical repair cost:$0 - $2,800

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Community Reported

High Confidence2,340 reportsLast reported by owners Oct 2025Reviewed Feb 2026

Community Reported

1,980 owners

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 14S17, expanded with 16V643, and additional recalls covering 2014-2016 Fusion specifically. Ford and Lincoln recalled over 2 million vehicles total across multiple model lines for this defect.

This issue also affects: Ford Edge, Ford Escape, Ford Focus

Common Symptoms

Door will not latch shut (bounces back when closed)
Door ajar warning chime or light with door apparently closed
Door opens while vehicle is moving
Wind noise from door area
Door latch mechanism feels loose or spongy

How to Fix

Ford Safety Recalls 14S17 / 16V643 / and subsequent recalls - dealers replace all affected side door latches at no charge. No mileage limit. Check safercar.gov or fordowner.com with VIN. The latches are replaced free regardless of current ownership. Multiple subsequent recalls covered additional years and models with the same issue.

What Owners Are Using

Parts and tips from 1,980+ owners who fixed this issue

NoteMultiple recalls cover this issue - check safercar.gov with your VIN to see ALL applicable recalls for your specific Fusion. This is a safety defect. Door opening at speed increases ejection risk. Free dealer repair required.
TipIf your door won't close before the recall is done: a temporary workaround is looping a strong zip tie through the latch striker to prevent door from opening while driving. This is emergency-use only - get to dealer ASAP for the proper fix.
TipFailure rate is highest in states with hot, humid climates (FL, TX, GA, AL). If you live in these states and have a 2013-2016 Fusion, prioritize this recall even if your doors currently close fine.
TipCheck NHTSA.gov for active recalls — repairs are performed free at authorized dealers

Typical repair cost:$0 - $0

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1,980+ owners have reported this issue

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Community Reported

High Confidence1,980 reportsLast reported by owners Jul 2025Reviewed Feb 2026

Community Reported

1,890 owners

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 extended warranty coverage to 7 years/84,000 miles for short block replacement per TSB 19-2139 and TSB 19-2375. 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.

This issue also affects: Volkswagen Eurovan, Audi A4 allroad, Audi Q5

Common Symptoms

White or gray smoke from exhaust, especially on cold starts
Engine misfires with P0300-P0303 codes (1.5L is 3 cylinders in newer versions; earlier is 4-cyl)
Coolant level dropping without visible external leak
Sweet smell from exhaust
Coolant reservoir bubbling or pressurizing excessively
Engine overheating
Rough idle that clears up as engine warms
No warning light in some cases before engine fails

How to Fix

Ford TSBs 19-2139 and 19-2375 cover short block and head gasket replacement under extended warranty (7 years/84,000 miles from warranty start date). Verify coverage at fordowner.com or call Ford Customer Relations 1-800-392-3673. Class action lawsuit for out-of-warranty reimbursement: lieffcabraser.com/defect/ford-coolant. Post-repair: Ford recommends monitoring coolant level and using only Motorcraft Orange coolant (VC-3-B).

What Owners Are Using

Parts and tips from 1,890+ owners who fixed this issue

NoteFord's 7yr/84k extended warranty for the 1.5L EcoBoost short block is YOUR money - call 1-800-392-3673 and reference TSBs 19-2139/19-2375 before authorizing any repair. Do not let dealers deny coverage without escalating. FusionEnergiForum has documented hundreds of successful warranty claims.
NoteUnlike most engine problems that show warning lights first, this failure can destroy your engine without a CEL. Some owners report zero warning signs before a hard start, white smoke, then engine death. Check coolant level monthly on any 2014-2019 Fusion 1.5L EcoBoost.
TipIf your dealer claims they cannot replicate the problem or denies the extended warranty, escalate to Ford Customer Relations and request a "Technical Assistance Request." Reference TSB 19-2139. The FTC investigated Ford's concealment of this defect - dealers are obligated to honor the extended warranty.
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Typical repair cost:$0 - $7,000

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1,890+ owners have reported this issue

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Community Reported

High Confidence1,890 reportsLast reported by owners Nov 2025Reviewed Feb 2026

Community Reported

1,400 owners

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).

This issue also affects: Chevrolet Bolt EV, Ford C-Max, Ford Mustang Mach-E

Common Symptoms

Reduced electric-only driving range
Decreased fuel economy (gradual decline)
"Check Hybrid System" warning on dashboard
Slower-than-normal acceleration or power loss
Battery charge indicator drops faster than normal
Unusual noise from battery compartment area
Vehicle fails to start (complete battery failure)
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.
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Typical repair cost:$1,500 - $7,000

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1,400+ owners have reported this issue

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Community Reported

Medium Confidence1,400 reportsLast reported by owners Feb 2026Reviewed Feb 2026

Frequently Asked Questions

What are the most common Ford Fusion problems?

According to Au7o's analysis of 7,610+ owner reports, the 2016-2016 Ford Fusion has 4 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, 4 are rated critical and should be addressed promptly.

Is the Ford Fusion reliable?

The 2016-2016 Ford Fusion has 4 known issues documented across 7,610+ owner reports. 4 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. 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 $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.

What is the 2013-2018 Ford Fusion Electric Power Steering (EPS) Failure - Sudden Loss of Assist?

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.

What is the 2013-2016 Ford Fusion Door Latch Pawl Spring Failure - Door Opens While Driving?

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.

What is the 2014-2019 Ford Fusion 1.5L EcoBoost Coolant Intrusion into Cylinders - Internal Engine Block Failure?

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.

What is the 2010-2020 Ford Fusion Hybrid High-Voltage Battery Degradation and Failure?

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.

2016 Ford Fusion Problems: 4 Issues Every Owner Should Know

All 4 Known Issues

2013-2018 Ford Fusion: Electric Power Steering (EPS) Failure - Sudden Loss of Assist#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2013-2016 Ford Fusion: Door Latch Pawl Spring Failure - Door Opens While Driving#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2014-2019 Ford Fusion: 1.5L EcoBoost Coolant Intrusion into Cylinders - Internal Engine Block Failure#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2010-2020 Ford Fusion: Hybrid High-Voltage Battery Degradation and Failure#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

Other Ford Models

Frequently Asked Questions

What are the most common Ford Fusion problems?

Is the Ford Fusion reliable?

How much does it cost to fix common Ford Fusion problems?

What is the 2013-2018 Ford Fusion Electric Power Steering (EPS) Failure - Sudden Loss of Assist?

What is the 2013-2016 Ford Fusion Door Latch Pawl Spring Failure - Door Opens While Driving?

What is the 2014-2019 Ford Fusion 1.5L EcoBoost Coolant Intrusion into Cylinders - Internal Engine Block Failure?

What is the 2010-2020 Ford Fusion Hybrid High-Voltage Battery Degradation and Failure?