FaultScore

FaultScore report

2009 Ford Fusion problems

Owners have filed 1,168 complaints about the 2009 Ford Fusion with NHTSA between 2009 and 2026. The largest single group is the brakes. Across this model's run it ranks 8 of 15 worst.

B

FaultScore 37/100

Higher is worse. Measured against the other years of the Ford Fusion.

How this is worked out

The numbers

1,168

Complaints

96

Crashes reported

8

Fires reported

42

Injuries reported

95,000 mi

Median mileage at failure

Half of reported failures happened before this

8%

Failed under 36,000 miles

Inside a typical bumper-to-bumper warranty

What kind of bad

The letter says how bad. This says what kind — whether this year drew an unusual number of complaints, unusually dangerous ones, or failures that arrived unusually early.

Complaint volume 30 vs 50 Severity 65 vs 50 Early failure 13 vs 50
The dashed ring is 50 — the national norm. Further out is worse.
Complaint volume — 30
Against the median year of the Ford Fusion. 50 means typical for this model; 100 means roughly double.
Severity — 65
12.5% of these complaints involved a crash, fire, injury or death, against a national rate of 9.7%.
Early failure — 13
8% of failures with a mileage on record happened under 36,000 miles, against a national rate of 29%.

How 2009 compares with every other Ford Fusion

Click any bar to open that year's report.

Complaints filed with NHTSA, by model year. Bar colour is the FaultScore grade: A B C D F ungraded

What breaks on a 2009 Ford Fusion

Every complaint is filed against a part. Follow any row for the complaints about that part alone.

Brakes 537 46.0%

42 crashes, 1 fires · median 100,700 mi

Airbags 359 30.7%

20 crashes, 0 fires · median 90,000 mi

5 crashes, 1 fires · median 76,000 mi

2 crashes, 3 fires · median 101,000 mi

7 crashes, 0 fires · median 47,000 mi

3 crashes, 0 fires · median 80,000 mi

2 crashes, 2 fires · median 66,500 mi

1 crashes, 0 fires · median 57,488 mi

Steering 16 1.4%

5 crashes, 0 fires · median 65,000 mi

Median failure at 79,200 miles

1 crashes, 0 fires · median 116,000 mi

Seats 10 0.9%

1 crashes, 0 fires · median 60,000 mi

Wheels 9 0.8%

1 crashes, 0 fires · median 85,771 mi

Tires 7 0.6%

2 crashes, 0 fires · median 19,000 mi

Suspension 6 0.5%

Median failure at 88,780 miles

Stability & Traction Control 5 0.4%

0 crashes, 1 fires · median 79,900 mi

Driver Assist & Collision Avoidance 3 0.3%

1 crashes, 0 fires · median 96,000 mi

Windows, Mirrors & Wipers 3 0.3%

Median failure at 18,000 miles

Lights 3 0.3%

Median failure at 40,000 miles

Equipment & Accessories 2 0.2%

1 crashes, 0 fires · median 78,700 mi

Seat Belts 2 0.2%

2 crashes, 0 fires · median 95,718 mi

Exactly what failed

NHTSA files every complaint against a named sub-assembly, not just a system. This is the difference between knowing it was "the engine" and knowing which part of it — the list to hand a mechanic.

Body 23 43.4%
Door 14 26.4%
Latch 6 11.3%
Automatic Emergency Braking 3 5.7%
ABS Warning Light 2 3.8%
Accelerator Pedal 2 3.8%
Control Unit/Module 2 3.8%
Oil/Lubrication 1 1.9%

When it fails

Odometer readings owners gave when they filed. About half of all complaints include one.

Under 1,000 miles 10 1.4%
1,000 – 9,999 miles 11 1.5%
10,000 – 24,999 miles 19 2.6%
25,000 – 49,999 miles 59 8.2%
50,000 – 74,999 miles 100 13.9%
75,000 – 99,999 miles 195 27.0%
100,000 – 149,999 miles 235 32.5%
150,000+ miles 93 12.9%

When owners complained

A spike years after the car went on sale usually means a part wearing out on schedule across the whole fleet — the kind of pattern no single owner can see from inside their own car.

Feb 2009 peak 56 Jul 2026

NHTSA investigations into the 2009 Ford Fusion

An investigation is the step before a recall: the agency has seen enough complaints to look into a pattern itself. An open one means it thinks something may be wrong and nothing has been fixed yet.

EA18002 Opened 18 Apr 2018 Closed 15 Jan 2021 SERVICE BRAKES, AIR:ANTILOCK:CONTROL UNIT/MODULE

Extended Braking Distance

On April 18, 2018, the Office of Defects Investigation (ODI) opened Engineering Analysis (EA) 18-002 to investigate reports of braking concerns in model year (MY) 2006-12 Ford Fusion and Lincoln MKZ, and MY 2006-11 Mercury Milan vehicles manufactured with Continental Automotive System?s ABS hydraulic control units (HCUs). Complainants report that after an ABS braking event (initiated by slippery or uneven surfaces) the brake pedal moved towards the floor and the vehicle stopping distance increased beyond driver expectations.Inside the HCU are four hydraulic normally closed (NC) valves with zin...

PE16017 Opened 20 Dec 2016 Closed 4 May 2018 SERVICE BRAKES

Extended Braking Distance

On December 20, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation (PE) 16-017 to investigate reports of braking concerns in model year 2007 through 2009 Ford Fusion and Mercury Milan vehicles.Complainants report that after an ABS braking event (caused by braking on a slippery or uneven surface) the brake pedal moved towards the floor and the distance in which the vehicle stopped increased beyond what was expected by the driver.The cause of the problem appears to be the Antilock Braking System (ABS) Hydraulic Control Unit (HCU), a component manufactured for Ford by C...

EA12009 Opened 12 Dec 2012 Closed 12 Jun 2014 VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

Floor mat interference with accelerator

On May 27, 2014, Ford Motor Company submitted recall 14E-028 (Ford recall #14S07) to correct a safety-related problem with certain driver's side Ford optional all-weather floor mats sold for use in model year 2006 through 2011 model year Ford Fusion, Mercury Milan, Lincoln Zephyr, and Lincoln MKZ vehicles built at Hermosillo Assembly Plant (HAP) from November 9, 2007, to October 31 ,2010.NHTSA testing determined that the original accessory all-weather mat with a single retention clip (Figure 1), may interfere with accelerator pedal return to idle with the mat retained by the clip and rotated c...

PE10019 Opened 28 May 2010 Closed 11 Jan 2013 VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

Accel Pedal Interference - Acc Floormat

Unsecured mats may interfere with accelerator pedal return to idle. A heel blocker in the floor pan provides a platform that may lift an unsecured mat into contact with the pedal. Ford introduced new pedals as a running change early in model year (MY) 2010 vehicles. Analysis of complaints received by ODI and Ford show elevated rates of pedal entrapment incidents in MY 2008 through early 2010 production vehicles. Incidents typically occur following hard pedal applications to pass slower traffic or when merging into faster traffic. Drivers allege continued high engine power after releasing the a...

Recalls on the 2009 Ford Fusion

A complaint is one owner's allegation. A recall is the point at which the manufacturer or a regulator agreed the defect is real and dangerous enough to fix for free — however old the car is.

Canada — Transport Canada

Canada runs its own recall programme, and its campaigns do not always mirror the American ones.

Recall 2021029 274,737 units in Canada

Airbag

Issue: On certain vehicles, long-term exposure to high absolute humidity and temperature, combined with high temperature cycling, may eventually degrade the propellant contained in the driver-front airbag. This could cause the airbag to deploy with more force than normal. If the airbag inflator ruptures, fragments could be propelled toward vehicle occupants or cause damage to the airbag assembly, preventing its proper function. Safety Risk: If the vehicle is involved in a crash requiring an airbag deployment, the airbag inflator could rupture and create a risk of injury. Corrective Action: Ford will notify owners by mail. The corrective actions for this recall are under development. Note: The Canadian climate results in the propellant degrading slowly. This recall is being conducted as a precaution to address future risk. It is expected that all airbag inflators will be replaced before their function would be affected.

Recall 2019665 54,292 units in Canada

Brakes

Issue: On certain cars, a problem with the hydraulic control unit for the anti-lock brake system (ABS) could cause increased brake pedal travel. Safety Risk: Increased brake pedal travel could increase the risk of a crash. Corrective Actions: The company will notify owners by mail and instruct you to take your vehicle to a Ford or Lincoln dealer to inspect the ABS module assembly. The system will be flushed with DOT 4 brake fluid, and if necessary, the hydraulic control unit will be replaced. Dealers will also replace the DOT 3 reservoir cap with a new DOT 4 cap.

Recall 2019005 300,898 units in Canada

Airbag

Issue: On certain vehicles, long-term exposure to high absolute humidity and temperature, combined with high temperature cycling, may eventually degrade the propellant contained in the passenger-front airbag. This could cause the airbag to deploy with more force than normal. If the airbag inflator ruptures, fragments could be propelled toward vehicle occupants or cause damage to the airbag assembly, preventing its proper function. Safety Risk: If the vehicle is involved in a crash requiring an airbag deployment, the airbag inflator could rupture and create a risk of injury. Corrective Actions: Owners will be notified by mail and instructed to take their vehicle to a dealer to have the passenger-front airbag inflator replaced. Note: The Canadian climate results in the propellant degrading slowly. This recall is being conducted as a precaution to address future risk. It is expected that all airbag inflators will be replaced before their function would be affected. Additional note: This recall supersedes recalls 2016-347 (Ford Safety Improvement Program 16S26), 2017-024 (Ford Recall 17S01) and 2018-035 (Ford Recall 18S01). Vehicles repaired under the previous recalls do not require repair under this recall.

Recall 2018035 36,727 units in Canada

Airbag

On certain vehicles, long-term exposure to high absolute humidity and temperature, combined with high temperature cycling, could eventually degrade the propellant contained in the passenger frontal airbag. This could cause the airbag to deploy with more force than normal. As a result, if the vehicle were involved in a collision that warrants airbag deployment, fragments could be propelled toward vehicle occupants, and the airbag assembly could be damaged, preventing proper function. These issues could increase the risk of injury. Correction: Dealers will replace the passenger frontal airbag inflator. Note: Canadian climate results in the propellant degrading slowly. The recall is being conducted as a precaution to address future risk, and is expected to replace airbag inflators before their function would be affected. Additional note: This recall is superseded by recall 2019005 (Ford Recall 19S01). Please see <a href="http://wwwapps.tc.gc.ca/Saf-Sec-Sur/7/VRDB-BDRV/search-recherche/detail.aspx?lang=eng&&rn=2019005">recall 2019005</a> for more information.

Recall 2016347 5,867 units in Canada

Airbag

Ford Canada is conducting a voluntary Safety Improvement Program involving passenger airbag inflators in certain vehicles that were originally sold or ever registered in certain high humidity areas of the United States equipped with Takata airbags. Ford will replace the driver or passenger inflator on affected vehicles, depending on the vehicle involved. Owners who believe their vehicles may have been originally purchased or registered in the states of New Jersey, Delaware, District of Columbia, Maryland, Pennsylvania, Ohio, Indiana, Illinois, Virginia, West Virginia, Kentucky, Missouri, Nebraska, Kansas, Oklahoma, Arkansas, Tennessee, North Carolina, Nevada, Arizona, New Mexico, California, Texas, Louisiana, Mississippi, Alabama, Georgia, South Carolina, Florida, Hawaii, Puerto Rico or the U.S. Virgin Islands should contact a Ford dealer. This action is not being conducted under the requirements of the Motor Vehicle Safety Act. Note: This Safety Improvement Program is superseded by recall 2019005 (Ford Recall 19S01). Please see <a href="http://wwwapps.tc.gc.ca/Saf-Sec-Sur/7/VRDB-BDRV/search-recherche/detail.aspx?lang=eng&&rn=2019005">recall 2019005</a> for more information.

Recall 2014195 2,810 units in Canada

Accessories

A safety defect may exist in Ford aftermarket all-weather floor mats sold as accessories or service replacement parts for 2006-2011 Ford Fusion, Lincoln Zephyr, and Lincoln MKZ vehicles. The floor mats are secured by a single retention device, which could allow the driver's floor mat to move out of position and interfere with the accelerator pedal.  If this occurs, the accelerator pedal could fail to return to idle.  This could result in a crash causing injury and/or property damage.  Correction: Dealers will replace Ford aftermarket all-weather floor mats with an updated design having two retention devices.

Recalls cover specific build ranges, so check your own vehicle by VIN at nhtsa.gov/recalls or, in Canada, Transport Canada.

Complaints that involved harm

Reports where the owner recorded a crash, a fire, an injury or a death.

Washington, DC Crash

SERVICE BRAKES

After activation of ABS brake system, brakes became "soft" and "spongy" with permanent increased braking time. As described in safety recall 19S54, this due to to a valve in the Hydraulic Control Unit (HCU) being stuck open. I received a letter from Ford Motor Company regarding this safety recall in 2011 informing of the defect and assuring "we will correct this condition." The vehicle was taken to Koons Ford (1051 E Broad St., Falls Church, VA, 22044; 703-241-7250) on 7/5/21 for repair. However, the HCU was not replaced, which appears to be the only remedy to this problem. Instead DOT 3 brake fluid was replaced with DOT 4 fluid, according to Koons Ford. However, after subsequent activation of the ABS brake system, the brakes became impaired again in the same way as before. I returned the car to Koons Ford on [XXX]. A "one-time" repair was performed pursuant to "customer satisfaction program" 21N11, as Ford acknowledged in a letter to dealers dated 12/7/21 that numerous customers were returning as the action prescribed in safety recall 19S54 did not repair the defective brakes. However, the HCU was not replaced. Service Advisor Kevin Lacki told me the HCU "passed" the inspection/diagnostic despite replication of the problem. I complained to Service Manager Rob Ryans who did nothing. I emailed the General Manager of the dealership twice, and he never responded. I called the manufacturer on [XXX] (case #[XXX]), but no action was taken. The problem of "soft" brakes and extended travel time quickly resurfaced and led to a vehicle accident in early 2023. The Ford Motor Company is employing a diagnostic that results in false "passes" for HCUs that should be replaced (and/or this dealership did not correctly perform the service actions). Even after "passing" Ford's diagnostic, the HCU valve(s) become stuck open after ABS activation. The safety recall should be investigated and the recall amended to replace faulty HCUs. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 55

NHTSA complaint #11617022 — an unverified report by a vehicle owner.

at 160,000 miles North Ridgeville, OH Crash

SERVICE BRAKES

The contact owns a 2009 Ford Fusion. The contact stated that the vehicle was experiencing extended brake pedal travel while driving. The contact stated that while driving at various speeds and depressing the brake pedal, the brake pedal traveled down to the floorboard, causing the braking distance to be extended. There was no warning light illuminated. Additionally, the contact stated that while her husband was pulling into the garage, the brake pedal was depressed. Still, the failure recurred, causing the vehicle to crash into the garage wall. There was no injury sustained. The vehicle was drivable. The contact later received notification of Ford Campaign Number: 21N11. The vehicle was taken to the dealer, where the brake fluid and the brake fluid cap were replaced; however, the failure persisted. The contact stated that the dealer had not replaced the HCU. The dealer was notified of the failure. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 160,000.

NHTSA complaint #11612491 — an unverified report by a vehicle owner.

Oak Park, MI Crash

AIR BAGS

My vehicle failed to stop which resulted to a car crash

NHTSA complaint #11511294 — an unverified report by a vehicle owner.

Oak Park, MI Crash

SERVICE BRAKES

My vehicle failed to stop which resulted to a car crash

NHTSA complaint #11511294 — an unverified report by a vehicle owner.

Oak Park, MI Crash

FORWARD COLLISION AVOIDANCE: AUTOMATIC EMERGENCY BRAKING

My vehicle failed to stop which resulted to a car crash

NHTSA complaint #11511294 — an unverified report by a vehicle owner.

Des Moines, IA Crash 1 injured

AIR BAGS

Extended brake travel that caused me to get into a car accident. Also my airbag did not deploy causing me to have a serious headache. I had two people in the vehicle with me. I pushed down on the brake pedal and it felt like it wasn’t stopping or it was stopping very slowly. I was driving straight the person in the white pontiac was trying to turn left. I had the right away no yield or stop sign, but she pulled out in front of me. Driver was a 16 year old girl

NHTSA complaint #11487467 — an unverified report by a vehicle owner.

The most recent complaints

In the owners' own words, exactly as filed with NHTSA.

Spring Lake, NC

EXTERIOR LIGHTING

my brakes had went out while i was driving home from work

NHTSA complaint #11751439 — an unverified report by a vehicle owner.

Spring Lake, NC

SUSPENSION

my brakes had went out while i was driving home from work

NHTSA complaint #11751439 — an unverified report by a vehicle owner.

Spring Lake, NC

SERVICE BRAKES

my brakes had went out while i was driving home from work

NHTSA complaint #11751439 — an unverified report by a vehicle owner.

at 110,000 miles Lexington, KY

SERVICE BRAKES, HYDRAULIC

The contact owns a 2009 Ford Fusion. The contact stated that the vehicle was taken to an independent mechanic for brake repairs, and after the repairs, the brake pedal felt spongy. The independent mechanic performed further inspections and diagnosed the vehicle with insufficient brake pressure due to a failure of the ABS hydraulic control unit. The manufacturer was notified of the failure. The contact related the failure to NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic); however, the VIN was not included. The approximate failure mileage was 110,000.

NHTSA complaint #11732434 — an unverified report by a vehicle owner.

at 95,000 miles Henrietta, NY

SERVICE BRAKES, HYDRAULIC

The contact owns a 2009 Ford Fusion. The vehicle was repaired under NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic), but the failure occurred. When the vehicle was retrieved from the dealer, the contact was informed that the vehicle had passed an inspection. The brake pedal was depressed approximately seventy percent down for the brakes to engage. The contact stated that the brake pedal was soft while depressed. No warning lights were illuminated. The vehicle was taken back to the dealer, but it was unknown if the vehicle was diagnosed. The contact was informed that the rear calipers needed to be inspected. However, the contact was unsure if the rear calipers were inspected. The contact stated that the vehicle remained at the dealer unrepaired and was awaiting a flush of the braking system. The dealer made the manufacturer aware of the issue. The zone manager informed the contact that a satisfaction program had expired. No additional assistance was provided. The failure mileage was approximately 95,000.

NHTSA complaint #11717314 — an unverified report by a vehicle owner.

Mobile, AL

SERVICE BRAKES

The ABS warning light came on while driving, and the brakes began to feel unsafe during normal stops. I later learned there is an open recall for the ABS module on my vehicle. When I took it to the dealership, they refused to perform the recall repair unless I paid out of pocket for a new ABS control module, even though the recall notice mentions this component. The issue affects braking performance and safety, especially on wet roads. The ABS system continues to malfunction, and the dealership’s refusal to complete the recall repair leaves the vehicle unsafe to drive.

NHTSA complaint #11692064 — an unverified report by a vehicle owner.

Hartsville, SC

SERVICE BRAKES

My car's brake pedal started not working properly. When trying to brake, the brake pedal goes down further than what it is supposed to and it takes longer than normal to brake, causing almost wrecks. It happens suddenly when trying to brake sometimes and it is very scary. There was a previous recall on the brake lines and it said they needed to be flushed out and all. I had this done to my car before and thought everything was okay. But it is not. I called Ford and they said there is currently a Customer Satisfaction Program that covers the repair of the Hydraulic control unit but it is limited to vehicles under 15 years old. My car is 16 years old so it does not qualify for this program. I asked why this wasn't a recall because it is such a big safety issue and they stated they couldn't make it a recall, it would have to be reported and issued from NHTSA. If the brakes/brake pedal is messing up and this is a known issue, then the vehicles' age should not matter. It should be recalled and fixed because this is such a huge safety concern and obviously a defect when manufactured. I don't have another car to drive and I'm sure there are numerous others in this same position and I feel it is imperative that this be looked into further and issued as a recall so people can remain safe and I'm sure this would save lives. I almost ran into a car today and it is extremely hazardous. It is very dangerous and scary and there is no warning light or anything indicating anything is wrong until driving it and it randomly happens. I have taken care of my car and had the previous recalls fixed but Ford knows this is an issue and very dangerous so it seems clear this needs to be issued as a recall.

NHTSA complaint #11680076 — an unverified report by a vehicle owner.

Charleston, WV

SERVICE BRAKES

I have recall 19S54 and called Ford. They made an appointment with Downtown Ford, Charleston, WV. The dealership said ford declined my recall repair due to not being able to get their machines to get any codes from my car. The ABS light is on. My mechanic said Ford should fix their recall. The recall says the D03 fluid must be changed to DOT 4 even if no problem found and if problem detected how to fix it! Ford declined because they can't get code reader to work on my car. They said it is a Preexisting Condition! My car is old but only has 24,800 miles and has been kept inside in a heated garage. The Downtown dealership said their hands are tied and would love to make my car safe. Their phone number is 304 344 1601. Please help me get my car fixed!!! I have called Ford multiple times and no help due to not having the codes from the dealership. Thanks!!!!

NHTSA complaint #11679035 — an unverified report by a vehicle owner.

Fairfield, OH

SERVICE BRAKES

I have noticed for some time in our 2009 Ford Fusion purchased used that the brake travel was longer than it should be. This results in the need to anticipate braking quicker and react faster to allow appropriate time to slow down. In doing some research I discovered a Ford recall 19S54 which was apparently replaced by a Ford CSP 21N11. I made an appointment to have this issue addressed by a Ford dealership and they said that the CSP expired in 2022 and the vehicle is no longer covered despite the persistence of the safety issue and the fact that it has not been repaired for this known problem. With a significant issue, such as braking, I believe the expiration should be extended to allow for Ford owners to have this known safety issue addressed appropriately by Ford.

NHTSA complaint #11627426 — an unverified report by a vehicle owner.

at 96,970 miles Van Burentownship, MI

AIR BAGS

The contact owns a 2009 Ford Fusion. The contact stated while driving 35-45 MPH, the brake pedal was depressed; however, the vehicle was slow to respond. The check brakes system message was displayed. The ABS warning light was illuminated. The contact received notifications of NHTSA Campaign Numbers: 19V904000 (Service Brakes, Hydraulic) and 21V158000 (Air Bags); however, the parts to do the recall repairs were not yet available. The local dealer was contacted. The dealer completed the air bag recall and diagnosed the vehicle and determined that the brake module and HECU module were corroded. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue, but no additional assistance was provided. The failure mileage was approximately 96,970. Parts distribution disconnect.

NHTSA complaint #11621936 — an unverified report by a vehicle owner.

at 96,970 miles Van Burentownship, MI

SERVICE BRAKES, HYDRAULIC

The contact owns a 2009 Ford Fusion. The contact stated while driving 35-45 MPH, the brake pedal was depressed; however, the vehicle was slow to respond. The check brakes system message was displayed. The ABS warning light was illuminated. The contact received notifications of NHTSA Campaign Numbers: 19V904000 (Service Brakes, Hydraulic) and 21V158000 (Air Bags); however, the parts to do the recall repairs were not yet available. The local dealer was contacted. The dealer completed the air bag recall and diagnosed the vehicle and determined that the brake module and HECU module were corroded. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue, but no additional assistance was provided. The failure mileage was approximately 96,970. Parts distribution disconnect.

NHTSA complaint #11621936 — an unverified report by a vehicle owner.

Washington, DC Crash

SERVICE BRAKES

After activation of ABS brake system, brakes became "soft" and "spongy" with permanent increased braking time. As described in safety recall 19S54, this due to to a valve in the Hydraulic Control Unit (HCU) being stuck open. I received a letter from Ford Motor Company regarding this safety recall in 2011 informing of the defect and assuring "we will correct this condition." The vehicle was taken to Koons Ford (1051 E Broad St., Falls Church, VA, 22044; 703-241-7250) on 7/5/21 for repair. However, the HCU was not replaced, which appears to be the only remedy to this problem. Instead DOT 3 brake fluid was replaced with DOT 4 fluid, according to Koons Ford. However, after subsequent activation of the ABS brake system, the brakes became impaired again in the same way as before. I returned the car to Koons Ford on [XXX]. A "one-time" repair was performed pursuant to "customer satisfaction program" 21N11, as Ford acknowledged in a letter to dealers dated 12/7/21 that numerous customers were returning as the action prescribed in safety recall 19S54 did not repair the defective brakes. However, the HCU was not replaced. Service Advisor Kevin Lacki told me the HCU "passed" the inspection/diagnostic despite replication of the problem. I complained to Service Manager Rob Ryans who did nothing. I emailed the General Manager of the dealership twice, and he never responded. I called the manufacturer on [XXX] (case #[XXX]), but no action was taken. The problem of "soft" brakes and extended travel time quickly resurfaced and led to a vehicle accident in early 2023. The Ford Motor Company is employing a diagnostic that results in false "passes" for HCUs that should be replaced (and/or this dealership did not correctly perform the service actions). Even after "passing" Ford's diagnostic, the HCU valve(s) become stuck open after ABS activation. The safety recall should be investigated and the recall amended to replace faulty HCUs. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 55

NHTSA complaint #11617022 — an unverified report by a vehicle owner.

Rocky River, OH

SERVICE BRAKES

While i was driving and the car hits a hole if the road, and i tried to brake so i can controll the car the breakes became uresponsive for the moment and after a few seconds when i try to brake again the travel space of the brake pedal is increased a lot and is near the end, and it takes a lot before the things return to normal( so it happens only when the car try to activate te ABS system).

NHTSA complaint #11616080 — an unverified report by a vehicle owner.

at 92,000 miles Virginia Beach, VA

SERVICE BRAKES, HYDRAULIC

The contact owns a 2009 Ford Fusion. The contact stated that while driving at various speeds, the brake pedal would depress to the floorboard without warning. The vehicle was taken to a dealer where the contact was informed that the Hydraulic Electric Control Unit (HECU) had failed and needed to be replaced. Upon investigation, the contact discovered NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic). The manufacturer was notified of the failure and the contact was informed that the vehicle was not included in the recall. The vehicle was repaired. The failure mileage was 92,000.

NHTSA complaint #11614828 — an unverified report by a vehicle owner.

at 160,000 miles North Ridgeville, OH Crash

SERVICE BRAKES

The contact owns a 2009 Ford Fusion. The contact stated that the vehicle was experiencing extended brake pedal travel while driving. The contact stated that while driving at various speeds and depressing the brake pedal, the brake pedal traveled down to the floorboard, causing the braking distance to be extended. There was no warning light illuminated. Additionally, the contact stated that while her husband was pulling into the garage, the brake pedal was depressed. Still, the failure recurred, causing the vehicle to crash into the garage wall. There was no injury sustained. The vehicle was drivable. The contact later received notification of Ford Campaign Number: 21N11. The vehicle was taken to the dealer, where the brake fluid and the brake fluid cap were replaced; however, the failure persisted. The contact stated that the dealer had not replaced the HCU. The dealer was notified of the failure. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 160,000.

NHTSA complaint #11612491 — an unverified report by a vehicle owner.

at 173,890 miles South Beloit, IL

ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS

The contact owns a 2009 Ford Fusion. The contact stated while driving at an undisclosed speed, the brake pedal depressed with no warning light illuminated. The vehicle was taken to the dealer however, the vehicle was not diagnosed or repaired. The contact was informed that the brake lines had been flushed. The contact stated while driving at an undisclosed speed, the failure recurred. The vehicle was taken to the dealer for a second time, and the vehicle was diagnosed with an HECU fuse failure. The contact was informed that the HECU fuse needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance. The failure mileage was approximately 173,890.

NHTSA complaint #11609064 — an unverified report by a vehicle owner.

at 173,890 miles South Beloit, IL

SERVICE BRAKES

The contact owns a 2009 Ford Fusion. The contact stated while driving at an undisclosed speed, the brake pedal depressed with no warning light illuminated. The vehicle was taken to the dealer however, the vehicle was not diagnosed or repaired. The contact was informed that the brake lines had been flushed. The contact stated while driving at an undisclosed speed, the failure recurred. The vehicle was taken to the dealer for a second time, and the vehicle was diagnosed with an HECU fuse failure. The contact was informed that the HECU fuse needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance. The failure mileage was approximately 173,890.

NHTSA complaint #11609064 — an unverified report by a vehicle owner.

Quartz Hill, CA

WHEELS

The potholes on the highway caused my tie rods and tires to explode!

NHTSA complaint #11606226 — an unverified report by a vehicle owner.

Quartz Hill, CA

STEERING

The potholes on the highway caused my tie rods and tires to explode!

NHTSA complaint #11606226 — an unverified report by a vehicle owner.

Quartz Hill, CA

SUSPENSION

The potholes on the highway caused my tie rods and tires to explode!

NHTSA complaint #11606226 — an unverified report by a vehicle owner.

Ostrander, OH

SERVICE BRAKES

Chapman Ford in Marysville, Ohio has had my car for ABS recall for almost a month now. They said they are waiting on the HYDRAULIC CONTROL UNIT HCU. Is this normal to take this long to fix.

NHTSA complaint #11600621 — an unverified report by a vehicle owner.

New Philadelphia, OH

SERVICE BRAKES

Ford dealership refuses to replace ABS HCU unit. Recall states that it will be replaced if defective. Dealership said that it is defective but not part of the recall. Shows that it is part of the recall.

NHTSA complaint #11577602 — an unverified report by a vehicle owner.

at 100,000 miles Bellwood, IL

LATCHES/LOCKS/LINKAGES:DOORS:LATCH

The contact owns a 2009 Ford Fusion. The contact stated that the front driver's side door became inoperable. The contact stated that the front driver's door failed to open. The contact stated that the door latch could be locked and unlocked; however, the front driver's door could not be opened. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 100,000.

NHTSA complaint #11558640 — an unverified report by a vehicle owner.

Willow Springs, MO

SERVICE BRAKES

Hcu fails and prolongs braking, brakes are often soft

NHTSA complaint #11556668 — an unverified report by a vehicle owner.

Bellwood, IL

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

The contact owns a 2009 Ford Fusion. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic, who determined that the exhaust manifold valve was stuck in the open position. The vehicle was repaired; however, the failure reoccurred. The vehicle was taken back to the independent mechanic, who determined that the exhaust manifold valve was stuck in the open position again. The vehicle was not repaired. The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was unknown.

NHTSA complaint #11545698 — an unverified report by a vehicle owner.