68 of the 1,580 complaints filed about the Ford Fusion Hybrid are about the fuel system — 4% of everything owners reported. The worst model year for it is 2010.
68
Complaints
4%
Share of all complaints
2
Crashes
3
Fires
FUEL/PROPULSION SYSTEM
EVAP blocking valve failed and car immediately went into limp mode on the highway. By doing this it could cause a crash. EVAP blocking valve also should last the life of the vehicle.
NHTSA complaint #11696645 — an unverified report by a vehicle owner.
FUEL SYSTEM, GASOLINE
The contact's granddaughter owned a 2013 Ford Fusion Hybrid. The contact stated that while her granddaughter was driving at an undisclosed speed, the driver looked in the rearview mirror and noticed black smoke coming from the rear seats of the vehicle. The contact stated that the driver's sons were in car seats in the rear seats of the vehicle. The driver immediately pulled over to the side of the road, exited the vehicle, and took her sons out of the vehicle. The contact stated that the entire vehicle then caught on fire. The contact stated that the driver's side of the vehicle was more burned than the rest of the vehicle. The fire was extinguished by the Fire Department, who informed the contact's granddaughter that the fire might have originated from the trunk of the vehicle. It was unknown whether a Police report or a Fire Department report was filed. The contact stated that the vehicle was towed and could be totaled. The driver's mother transported the driver and her sons to the emergency room due to smoke inhalation. It was unknown whether injuries were sustained. The dealer and the manufacturer were not notified of the failure. The failure mileage was unknown.
NHTSA complaint #11664680 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
On May 26, 2023, after I started moving from stop at a traffic light, I rear ended the vehicle in front of me when it came to a sudden stop. My speed was between 25 - 35 mph at most. My front and side curtain airbags deployed, the hood was crumpled and fascia was damaged as expected. However after 10 minutes or so, flames started coming from underneath the hood and within a few minutes the engine compartment was on fire. The Fire Department arrived and put out the fire but had to break the windshield and rip off the fender to aim the fire hoses.
NHTSA complaint #11526971 — an unverified report by a vehicle owner.
FUEL SYSTEM, GASOLINE
The contact owns a 2018 Ford Fusion. The contact stated when the vehicle was started, the instrument cluster display failed to illuminate. The contact stated that the cluster had intermittently lost functionality. The contact stated that he researched online and related the failure to Technical Service Bulletin Number: 20-2363 APIM module. Additionally, the contact stated that the fuel filler pump and fuel door actuator had started to lose functionality. The contact stated that he was unable to completely fill the fuel tank. The contact stated that the check engine warning light was illuminated. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the APIM module needed to be replaced and that the fuel filler pump and fuel door actuator need to be replaced. The vehicle had not been repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 111,000.
NHTSA complaint #11526630 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
The fuel door not opening. The dashboard shows fuel door opening and it doesn’t. After watching some YouTube videos at the gas station not knowing what else to do I have to now open the trunk and use the emergency release. Nothing seems wrong once it is opened. I found out this is a problem for others with knowing other people posted videos on YouTube with the same problem.
NHTSA complaint #11454506 — an unverified report by a vehicle owner.
HYBRID PROPULSION SYSTEM
The contact owns a 2010 Ford Fusion Hybrid. The contact stated that while in traffic on an incline, the hybrid battery was running however, the vehicle failed to accelerate. The message to “pull over safely, check charging system” was displayed. The vehicle was pulled off the road. The vehicle was towed to the local dealer to be diagnosed. The contact was informed that the wiring harness needed to be replaced because there was no power going to the vehicle. The vehicle was not repaired. The manufacturer was not contacted. The approximate failure mileage was 111,000.
NHTSA complaint #11438517 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
DUE TO A DESIGN FLAW, THE CAR'S COMPUTER SYSTEM CANNOT ACCEPT AN INDICATION OF MORE THAN ONE DIGIT IN THE "AGE" ENTRY. FOR THIS REASON, THE ELECTRIC HIGH VOLTAGE BATTERY STOPS WORKING WHEN THE CAR APPROACHES 10 YEARS OF AGE, CAUSING A SERIOUS AND DANGEROUS HESITATION IN THE DRIVE TRAIN WHEN STARTING FROM A DEAD STOP CREATING A VERY DANGEROUS DRIVING CONDITION, ESPECIALLY WHEN MAKING A CROSS-TRAFFIC TURN. REPEATED REQUESTS FROM MY FORD DEALER TO FORD MOTOR COMPANY FOR AN EXPLANATION OF HOW TO FIX THIS PROBLEM WERE UNSUCCESSFUL. MY LETTERS TO FORD SENIOR MANAGEMENT HAVE GONE UNANSWERED FOR SEVERAL MONTHS. I HAVE SINCE LEARNED HOW TO RESET THE "AGE" DATA, AND MY DEALER HAS FOLLOWED THE INSTRUCTIONS TO ELIMINATE THE CONDITION. FORD SHOULD BE REQUIRED TO ISSUE A RECALL FOR CORRECTION OF THIS KNOWN DESIGN FLAW.
NHTSA complaint #11233861 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
THE VEHICLE NO LONGER ACCELERATES UNDER BATTERY POWER. TIME DELAY IN ACCELERATION DUE TO DECREASED BATTERY POWER, CAUSING A SAFETY ISSUE.
NHTSA complaint #11219164 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
THE VEHICLE NO LONGER OPERATES IN ELECTRIC MODE, USING THE HIGH VOLTAGE BATTERY TO POWER THE ELECTRIC MOTOR. THIS IS A MAJOR SAFETY CONCERN SINCE THERE IS NO ASSIST FROM THE ELECTRIC DRIVE MOTOR. WHEN ACCELERATING FROM A DEAD STOP, THERE IS A SIGNIFICANT LAG BEFORE THE GASOLINE MOTOR ENGAGES AND PROVIDES ENOUGH POWER TO MOVE THE CAR. THIS IS ESPECIALLY PRONOUNCED WHEN MAKING A LEFT TURN AGAINST TRAFFIC.
NHTSA complaint #11219222 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
THE VEHICLE WILL NO LONGER OPERATE IN ELECTRIC MODE. THIS IS A MAJOR SAFETY CONCERN SINCE THERE IS NO ASSIST FROM THE HIGH-VOLTAGE BATTERY POWERED ELECTRIC DRIVE MOTOR. UPON ACCELERATING FROM A DEAD STOP, THERE IS A SIGNIFICANT LAG BEFORE THE ICE KICKS IN AND PROVIDES ENOUGH POWER TO MOVE THE VEHICLE.
NHTSA complaint #11218938 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
VEHICLE WON'T ACCEPT GAS OR IF IT DOES VERY SLOWLY. SOMETIMES WILL ALSO SPIT GAS OUT. JUST AT 38,000 MILES. FORD SAYS IT ISN'T UNDER WARRANTY. QUICK SEARCH APPEARS VERY COMMON DANGEROUS ISSUE.
NHTSA complaint #11207543 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
EMISSION RECALL14E02 WHICH STATES VET MAY BE EQUIPPED WITH AN IMPROPERLY FUNCTIONING ON-BOARD EMISSION-RELATED DIAGNOSTIC SYSTEM THAT DOES NOT MEET CALIFORNIA STANDARDS AND REGULATIONS, WHICH ALSO APPLY IN MASSACHUSETTS, MAINE, NEW YORK AND VERMONT. DISABLED EMISSION-RELATED MONITORS ARE UNABLE TO WARN OF AN EMISSION CONTROL MALFUNCTION. VEHICLE WHEN BEING OPERATED SMELLS AND CAUSES OCCUPANTS TO CHOKE.
NHTSA complaint #11193114 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
THIS CAR HAS BEEN IN TWICE FOR A CAM POSITION SENSOR. THE FIRST TIME THE PART TOTALLY FAILED AND LEFT US ON THE ROAD SIDE ON A VERY DANGEROUS STRETCH OF HWY 101 AND WAS REPLACED. 1708 MILES LATER THE CHECK ENGINE LIGHT CAME ON AGAIN. THE CODE WAS P0340 AGAIN. WE WERE TOLD THAT THE ISSUE COULD NOT BE DUPLICATED THROUGH A DEALER ROAD TEST AND WE WERE CHARGED $190.00 FOR THE DIAGNOSTICS. THE FIRST TIME THIS ISSUE OCCURRED, WE HAD BROUGHT THE VEHICLE IN FOR A SAFETY RECALL. WHEN WE PICKED THE CAR UP, THIS WAS THE FIRST INSTANCE OF THE FAILURE OF THIS COMPONENT. THIS HAS CAUSED US GRAVE CONCERN. MY WIFE HAS MS AND CAN'T BE LEFT ON THE ROADSIDE. WE BELIEVE THIS VEHICLE HAS THE POTENTIAL TO BE UNSAFE, AND FORD WILL NOT STAND BEHIND THEIR REPAIRS AS THE COMPUTER SHOWS THE CODE THAT WOULD STATE THE ISSUE HAS HAPPENED AGAIN, BUT BECAUSE THE SERVICE DEPARTMENT COULD NOT CAUSE THE CODE TO OCCUR A THIRD TIME, THAT EVERYTHING IS WORKING WELL. AGAIN, WE BELIEVE THIS IS WRONG AND WISH TO MAKE THE PUBLIC AWARE OF A VERY REAL SAFETY ISSUE. WE HAVE CONTACTED THE DEALER ABOUT THE ISSUE. OUR SERVICE ADVISER IS [XXX] FROM MOCK FORD (SHOULD BE NOTED THIS IS NOT HER FAULT NOR I BELIEVE MOCK FORD) AND THE FORD REP IS [XXX], 866-631-3788 X77756 . WE DO NOT KNOW AT THIS TIME IF THE ISSUE HAS BEEN REMEDIED. ONLY THAT THROUGH A TEST DRIVE IT COULD NOT BE DUPLICATED. THE COMPUTER LOG SHOWS THE INCIDENTS. SHOULD WE JUST IGNORE THIS AND HOPE FOR THE BEST? INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).
NHTSA complaint #11191466 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
TWO DAYS AFTER GETTING GAS MY ENGINE LIGHT CAME ON. IT STAYED ON FOR ABOUT A WEE AND TURNED OFF. THIS KEPT HAPPENING EVERYTIME I GOT GAS S I TOOK IT TO THE DEALERSHIP AND WAS TOLD SOMETIMES THE CAP STICKS AND IT'S A COMMON THING THAT DOESNT REQUIRE ANY REPAIRS AND THEY RESET IT. THIS HAPPENED FOR ALMOST A YEAR. I TOOK IT BACK AND THIS TIME THEY CLAIM I NEEDED A NEW VAPOR MANAGEMENT VALVE. OF COURSE MY CAR IS LESS THAN 36,000 MILES BUT THE 3 YEARS ARE UP AS OF TWO MONTHS AGO. I CALLED FORD AND THEY SAID IT WAS COVERED UNDER WARRANTY BECAUSE I HAD THE PROBLEM BEFORE THE 3 YEARS. WHEN I GET TO THE DEALERSHIP TO PICK UP MY CAR THEY WANT ME TO PAY FOR THE REPAIR. I CALL FORD BACK AND ASK THEM TO SEND AN AUTHORIZATION NUMBER TO THE DEALERSHIP AND NOW ALL OF A SUDDEN IT'S NOT UNDER WARRANTY.
NHTSA complaint #11189803 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
THROTTLE BODY STUCK CLOSED WHILE DRIVING FORCING ENGINE POWER TO BE REDUCED THEN TO ZERO. HAD TO PULL OVER TO SIDE OF ROAD. PART WAS REPLACED HOWEVER, NOTICED THAT THE HYBRID MODEL WAS NOT SUBJECT TO A RECALL AND WARRANTY WAS NOT EXTENDED. SYMPTOMS WERE THE SAME AS FORD LETTER ISSUED TO DEALERS ON MARCH 16, 2015
NHTSA complaint #11155893 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
WHILE USING FULL ACCESSORY POWER WITH THE ENGINE OFF, THE CAR WILL ALLOW YOU TO CHANGE THE GEAR SHIFT DIAL TO DRIVE. THE CAR IS ABLE TO MOVE IN THIS POSITION, BUT THE GAS PEDAL WILL NOT WORK. THE 'READY TO DRIVE' LIGHT IS.NOT ON.
NHTSA complaint #11150783 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
THE 2010 FORD FUSION HYBRID KEEPS GOING INTO "LIMP" MODE EVEN ON THE HIGHWAY. THIS CAUSES POWER LOSS AND LOSS OF ACCELERATION. THIS CAN BE AT ANYTIME. THIS KEEPS HAPPENING MORE AND MORE AND FORD DOES NOT KNOW THE CAUSE OR RESOLVE.
NHTSA complaint #11114046 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
AUTO SHUTS DOWN WHILE DRIVING,NO POWER..MUST STOP,SHUT OFF IGNITION AND RESTART THE ENGINE...CAR SEEMS TO REVERT TO NORMAL AFTER TURNING BACK ON.HAS OCCURED MANY TIMES..LOCAL FORD DEALER IS AWARE OF PROBLEM AND HAS INSTALLED A COUNTER..THE COUNTER CLOCKS UP WHEN THIS OCCURS BUT RESETS WHEN CAR IS STOPPED AND RESTARTED...THIS IS A POTENTIALLY DANGEROUS PROBLEM AS THIS HAS HAPPENED IN TRAFFIC AND DRIVER HAS NO POWER,MUST PULL OUT OF TRAFFIC,RESTART AND GO AGAIN...
NHTSA complaint #11104213 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
THE CAR STOPPED WHILE DRIVING THROUGH THE FREE WAY@55 MPH. DO NOT ACCELERATE. THE ENGINE VIBRATE AND CAR SHAKING. AFTER TURN OFF AND TURNED ON THE ENGINE FEW TIMES, THE CAR WAS PERFORMING FINE. THE DEALER CHECKED. NO MALFUNCTION CODE WAS DETECTED. THEY TOLD THAT 95% IT IS DUE TO THE CLOGGING OF ELECTRONIC THROTTLE VALVE. SO REPLACED. I ASKED AND THEY SHOWED THE OLD ONE. I OBSERVED NO CLOGGING OR GREASE ON THE VALVE. IT WAS CLEAN. THIS PARTS/OR THROTTLE VALVE SYSTEM WAS FUNCTIONING. THE CAR HAS 85,000 MILE.I SPOKE TO FORD ABOUT THIS SAFETY ISSUE. THEY DON'T DO ANY BECAUSE THE WARRANTY EXPIRE.
NHTSA complaint #11092289 — an unverified report by a vehicle owner.
FUEL/PROPULSION SYSTEM
4/18/17 I WENT TO LEAVE MY HOME IN MY 2012 FORD FUSION HYBRID AND AS I PULLED OUT OF MY HOUSE AND PROCEEDED TO MY FIRST STOP LIGHT, I WAS IN MOTION GOING DOWNWARD ON A SLIGHT HILL IN MY NEIGHBORHOOD AND I NOTICED MY BREAKS JUST DROP TO THE FLOOR AND BREAK PEDALS SEEMED TO STIFFEN IN THEIR FLEXIBILITY AND I WAS HEADED STRAIGHT FOR A RED LIGHT. I WAS EXTREMELY TERRIFIED AND DID THE BEST I COULD TO MAINTAIN THE CAR UNDER MY CONTROL.. I NOTICED THE DASH WAS FULL OF RED LIGHTS SAYING 'CHECK BREAK SYSTEM ' AND ABS LIGHTS WERE ON AS WELL ASS 2 TRACTION CONTROL LLIGHTS. HAD WEATHER CONDITIONS BEEN DIFFERENT AND MY SON BEEN IN THE CAR THIS COULD HAVE POSED A THREAT TO OUR LIVES. IT'S EXTREMELY DANGEROUS AND QUITE UNPLEASANT TO IMAGINE WHAT FEELS LIKE LOOSING YOUR BREAKS. BUT I DON'T BELIEVE THIS IS THE CASE!! UP UNTIL NOW I HAVE NOT HAD ANY ISSUES WITH MY BREAKS, NEVER SHOWN ANY SIGNS TO BE CONCERNED WITH ABS THE CAR HAS 32K MILES ON IT SHOULDN'T NEED BREAKS OR MASTER C IT'S A FAULTY ABS MODULE.. I DON'T BELIEVE ANYTHING IS ACTUALLY WRONG WITH THE CAR. AFTER I PULLED OVER I TURNED CAR OFF AND BACK ON AFTER CHECKING IN OUT A FEW TIMES I STARTED THE CAR AND NOTICED IT LOOKED NORMAL FOR A SECOND UNLIKE OTHER TRYS SO I STARTED TO DRIVE BREAKS FELT FINE CAME BACK UP LIKE NORMAL AND CAR WORKED BUT AFTER 20 SECONDS OF DRIVING IT' CUT BACK OUT FLASHING RED WARNING SIGNS AND BEEPING. BREAKS SINK DOWN AND BECOME HARD TO CONTROL. I SEE THIS IS COMMON PROBLEM I NEED THIS FIXED I'M EXTREMELY UP SET HOW AFTER 32K THIS GOES OUT AND IS NOT A SMALL FIX.
NHTSA complaint #11088984 — an unverified report by a vehicle owner.