2016 Ford Fusion brake problems

SERVICE BRAKES

I would like to make a complaint for malpractice during a recall repair. I was notified on aug 4, 2026 that after the dealership did the recall 23S12 brake hose that during the test drive that my master seal and brake booster started to leak and needs to be replaced. They asked me if i have had any brake problems and we have not. They wanted to charge me over $1000. I declined because i had no issues prior to my vehicle going to them. They then stated they would complete the job for a little over $600. i declined. They said they reached out to Ford to see if they could cover the master seal and brake booster but they said FORD declined. However, they never asked ford. I have the OASIAS report verifying that information. They did not inform me that this is a saftey issue, they never said do not drive the vehicle, the documentation they gave me does not warn this is a issue. However, on the way home I realized I had no brakes. I assumed my vehicle would be in the same shape as i had it taken in and I would have brakes. I do not. I brought my vehicle to my home called the dealership who basically said unless i want to pay for the job in full i am on my own. I need help. I have the information on July 30 when they did the original inspection and they did a brake inpection and there is no mention of any brake issues. However, after the recall the inspection was done, they took a camera went into the brake booster and master seal. All of this was done with out informing us until it came time to pay.

NHTSA complaint #11756989 — an unverified report by a vehicle owner.

SERVICE BRAKES

The brake booster vacuum pump coupler broke off of the vacuum pump and a piece of the coupler was left stuck in the camshaft. This caused the brakes to become very stiff and hard to push down to stop the vehicle. It wasn't inspected by anyone. No warning messages or icons appeared on the dash. Car had to be towed.

NHTSA complaint #11753536 — an unverified report by a vehicle owner.

SERVICE BRAKES

The engine experienced a sudden failure that caused the vehicle to become completely inoperable. Prior to the failure, the vehicle exhibited intermittent hesitation, rough idling, and loss of power during acceleration. These symptoms began several weeks before the complete failure. No warning lamps were illuminated at first, but shortly before the breakdown, the vehicle displayed a check engine light and a “Service Engine Soon” message. While driving, the vehicle abruptly lost power and became unsafe to operate. I was forced to pull over immediately, which created a safety risk to myself and other drivers due to the sudden deceleration and inability to maintain speed in traffic. The vehicle would not restart afterward. A repair facility has confirmed that the engine has suffered a major internal failure and requires replacement. The estimated cost of repair starts upwards of $5,000. The vehicle is currently non‑drivable and remains available for inspection. The issue has been reproduced and confirmed by an independent service center. The vehicle has not yet been inspected by the manufacturer, police, or insurance representatives. However, I have found multiple similar complaints from other owners reporting the same type of powertrain failure, suggesting a potential pattern or defect affecting safety.

NHTSA complaint #11752956 — an unverified report by a vehicle owner.

SERVICE BRAKES

After hitting 100,000 mile my car electronics failed and caused my steering to fail and all other safety equipment like airbags and brokering system

NHTSA complaint #11743385 — an unverified report by a vehicle owner.

SERVICE BRAKES

The entire engine/motor

NHTSA complaint #11740520 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

The contact owns a 2016 Ford Fusion. The vehicle was serviced under NHTSA Campaign Numbers: 23V162000 (SERVICE BRAKES, HYDRAULIC) and 19V632000 (STEERING), but the failure persisted. A month after the recall repairs were completed, while driving at an undisclosed speed, the brake warning light was illuminated and blinked, and the steering wheel failed to function as intended. The contact used force to veer the vehicle to the side of the road. Once the contact was able to pull to the side of the vehicle, the engine was turned off. The contact called her boyfriend, who drove to the site of the incident and assisted the contact and pushed the vehicle to the residence. The dealer was contacted and at first refused to inspect the vehicle. The contact called the dealer again, and the dealer sent a mobile mechanic to the residence. However, no cause for the failure was found. The contact was informed that a diagnostic test would be performed on the vehicle. However, the contact would be responsible for the bill. The vehicle remained at the residence unrepaired. The manufacturer was not made aware of the failure. The failure mileage was unknown. 

NHTSA complaint #11736657 — an unverified report by a vehicle owner.

SERVICE BRAKES

I called way scarff ford to have the safety recalls taken care. Got my appointment, stopped the car off in the morning. They kept the car for 3 days and after the 3rd day they said everything is good to go. Go there in Auburn WA couldn't find my car. Took 4 people or including myself. Then it took another half hour to 45 min to find my car. Go get in the vehicle and something doesn't seem right. Everything still felt the same. I look under the hood and find that the the recalls for the cable bushing wasn't corrected so let led me to think that the other recalls were not completed. Befote calling ford corporate to have this issue taken care of we called [XXX] in enumclaw to have this taken care of. Since the car was at way scarff my car started to act funny. Lean idle, really rough idle vibration with now a code P0299 which is the underboost. I do not think they hooked the hoses up correctly. So now my car is acting really funny. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11729819 — an unverified report by a vehicle owner.

SERVICE BRAKES

My vehicle has multiple active safety recalls that remain unrepaired. I have already contacted the dealership and attempted to have these issues addressed, but I have experienced delays and a lack of response. The front brake hose recall presents a serious safety risk, as it could rupture and cause a brake fluid leak, leading to reduced braking ability and increased stopping distance. Additionally, the rear view camera recall affects visibility when reversing, as the camera may display a blank or distorted image.I have already filed a complaint with NHTSA regarding these unresolved recalls. One of the recalls currently does not have a remedy available, and the other has not been completed despite my efforts to schedule repairs.These unresolved safety issues put me and others at risk, and I am concerned about the lack of timely action to correct them.

NHTSA complaint #11726247 — an unverified report by a vehicle owner.

SERVICE BRAKES

The vehicle is a 2016 Ford Fusion with 70,000 miles when this happened happened the first time. I pushed on the brakes and the pedal went to the floor. I had just enough braking power to stop the vehicle. The danger is obvious, I had no brakes but I was going slow on local roads. I had the vehicle towed to an independent repair shop where they diagnosed failure of the right rear brake caliper. They replaced the caliper, hoses and ceramic brake pads at a cost of about $600. All was good for about 1500 miles when the exact same thing happened, except now it was the driver's side caliper. Fortunately, once again, I was driving on local roads at low speeds and by holding the pedal totally against the floor, I was able to drive over the curb onto a lawn without hitting anyone. if I had been on an Interstate, I don't see how it wouldn't have resulted in a serious accident. I have no parts or pictures from the first failure, only the receipt for work done, but the car is in the same repair shop as I write this and I will have the failed parts and pictures when I pick up the vehicle on Monday, 12/29/25. Two brake caliper failures, with no warning, at 70,000 and 71,500 miles is a scary scenario. I have no confidence in the vehicle's safety and will be disposing it as soon as it's fixed. Your system won't allow me to put in two dates for the two failures but the first was on 01/24/25 at approximately 70,000 miles and the second was today 12/26/25 at approximately 71,500 miles. The vehicle is registered to me at the address listed on this form but I am a snowbird and the vehicle is in Naples Florida at my winter residence.

NHTSA complaint #11707134 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

The contact owns a 2016 Ford Fusion. The contact received notifications of NHTSA Campaign Numbers: 23V162000 (Service Brakes, Hydraulic) and 25V695000 (Back Over Prevention). The contact stated that the dealer had sent a mobile mechanic to the contact's residence to complete the recall repair of NHTSA Campaign Number: 23V162000 (Service Brakes, Hydraulic). During the day, the contact checked the residence ring camera and noticed that two mobile mechanics had stopped by the residence to work on the brakes. The contact stated that after a while, both mechanics left the residence and left the hood of the contact's vehicle lifted. The contact stated that the mechanic returned after a while and continued servicing the vehicle. The contact noticed that the mechanic had difficulty with the lug nuts on the wheels and had to fracture the lug nuts to remove the wheels. The contact noticed that the mechanic had reinstalled the fractured lug nuts back on both front wheels. The contact had not test-driven the vehicle. The manufacturer was not made aware of the issue.  The mileage was unknown.

NHTSA complaint #11706874 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

The contact owns a 2016 Ford Fusion. The contact received notifications of NHTSA Campaign Numbers: 23V162000 (SERVICE BRAKES, HYDRAULIC) and 25V695000 (BACK OVER PREVENTION). However, the parts to do the recall repairs were not yet available. The contact stated that the rearview camera displayed a distorted image while the vehicle was in reverse(R). The contact stated that the failure obstructed the driver's visibility, which prevented the driver from safely operating the vehicle. The message "Rear-view Camera not Available" was displayed. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact stated that the vehicle was purchased in 2025, and the rearview camera was not functioning as intended. The failure mileage was approximately 116,000.

NHTSA complaint #11700116 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

The contact owned a 2016 Ford Fusion. The contact received notifications of NHTSA Campaign Numbers: 23V162000 (Service Brakes, Hydraulic) and 25V695000 (Back Over Prevention); and requested to be removed from the recall distribution list because the contact no longer owns the vehicle. The dealer was contacted.

NHTSA complaint #11697569 — an unverified report by a vehicle owner.

SERVICE BRAKES

I had a recall on my car for brake hoes was leaking i fixed it but now brake fluid is leaking from right passenger side calliper after recall was done on my car and the recall done by Purvis Ford Inc 11335 Patriot Hwy, Fredericksburg, VA 22408 and they are not taking the responsibility that it happened after the recall done by them

NHTSA complaint #11690566 — an unverified report by a vehicle owner.

SERVICE BRAKES

My cars brake lights will not turn off and while pressing on the gas to accelerate today 8/26/25, the braking system randomly just slows my cars down while I’m driving. The brake pedal bumper was previously recalled for the Ford Fusion as told to me by Ford mechanic. But because my vin isn’t associated with the recall Metro Ford stated they could not fix the problem and I was sent back out on the road with a known recall issue.

NHTSA complaint #11683049 — an unverified report by a vehicle owner.

SERVICE BRAKES

I own a 2016 Ford Fusion and the brake pedal stop bumper disintegrated and fell onto my floorboard. As a result, my brake lights stayed on, draining my battery. When I tried to drive, my car would not accelerate over 20 mph, and I barely made it home safely. I where it's extreme humid and salty air are constant, the same conditions identified in Ford’s 22S02 recall. Ford has stated my vehicle is not included, but this is a clear safety hazard identical to the recall issue. I request that NHTSA investigate and include my vehicle in the 22S02 recall.

NHTSA complaint #11675595 — an unverified report by a vehicle owner.

SERVICE BRAKES

The ABS module is faulty and light will come on at random times and makes steering hard and braking on right side of vehicle is hard. I have taken it to Raceway Ford of Hartsville and they are having a hard time getting the part due to it being called obsolete but I think it needs to be on the recall list as well due to it being a safety concern on my vehicle.

NHTSA complaint #11658864 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

The contact owns a 2016 Ford Fusion. The contact stated that the exterior brake lights remained on after turning off the vehicle. The vehicle was taken to the dealer, where the contact was informed that the vehicle was not covered under NHTSA Campaign Number: 22V011000 (Service Brakes, Hydraulic). The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 160,000.

NHTSA complaint #11621899 — an unverified report by a vehicle owner.

PARKING BRAKE

The contact owns a 2016 Ford Fusion. The contact stated that on two occasions while the vehicle was parked, the check engine, ABS, parking brake, traction on/off, and power train warning lights illuminated. Additionally, the steering wheel became firm. The vehicle was taken to an independent mechanic where it was diagnosed that the electronic power steering module needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 165,000.

NHTSA complaint #11617489 — an unverified report by a vehicle owner.

SERVICE BRAKES

The left rear caliper has been replaced 3 times in the last 6 months and is currently in the shop for a 4th. This locks up for no reason and ruins the brake pad and the rotor and I have now replaced all of that 3 times as well and the brake hose line.

NHTSA complaint #11611166 — an unverified report by a vehicle owner.

SERVICE BRAKES

This failure narrowly resulted in a serious accident when my vehicle applied the brakes without warning and dropped the speed to below 40 mph on the Highway! I was extremely fortunate not to have been closely followed by a large semi at the time. I researched on my own and found this was a known defect: Ford Recall reference #22S02 (21C24) March 2022. includes vehicles built in Hemosillo plant from Oct 2013 thru 6 April 2015. my fusion was built there on 2 April 2015 but was not included in the March 2022 recall so I was never notified. Apparently this was a known defect and on going problem since Ford issued SSM 50328 to cover various vehicles built from 2013 to 2021 (Includes 2013-2017 Fusion/MKZ). I was able to drive the vehicle safely on back roads to a local Ford dealer where the problem was addressed. I submitted a request for refund to Ford and advise them of this continuing safety issue that should have been addressed with a properly expanded recall. Ford denied my request and tried to avoid the ongoing safety issue claiming it was an "out of warranty" matter.

NHTSA complaint #11609877 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

The contact owns a 2016 Ford Fusion. The contact stated that while her son was driving at approximately 65 MPH, the "Low Brake Fluid" warning light was blinking. The contact attempted to slow down and depressed the brake pedal, and the brake pedal was depressed to the floorboard and the vehicle failed to respond as needed. The contact stated that her son was able to stop the vehicle and called for assistance. The contact stated that she drove to his location had a quart of brake fluid and refilled the brake fluid reservoir. The vehicle was driven back to her residence. The contact noticed that brake fluid was forming a puddle underneath the driver's side rear wheel well. The contact stated that NHTSA Campaign Number: 23V162000 (Service Brakes, Hydraulic) repair had been completed in November 2023; for the front brake lines. The contact related the failure of the rear driver’s side brake failure to the recall. The vehicle was not taken to a dealer or an independent mechanic. The vehicle was not diagnosed or repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.

NHTSA complaint #11604441 — an unverified report by a vehicle owner.

SERVICE BRAKES

While driving to pick up my wife from work, I was not able to accelerate past 35-40 mph. Upon arriving home, we noticed that the brake lights were staying on. We took the car to our local Ford dealer and was told it was a stop lamp switch pad that had broken off and that, unfortunately, the pad was not sold separately, I would need to purchase the entire brake pedal assembly and pay for the labor to have it installed ($585.11). Shortly after this occurred I found that 2013-2015 models of the Ford Fusion (same body) had been recalled for the same issue. The pad becomes brittle and breaks apart when the car is predominantly in hot and humid climates. I live in Deep South Texas where temperatures and humidity hover around 100 degrees for 10 months a year. I believe other model years should be added to the recall list. Not being able to accelerate could have caused an accident.

NHTSA complaint #11595757 — an unverified report by a vehicle owner.

SERVICE BRAKES

There is an Unrepaired Recall associated with my car. The Manufacturer Recall Number is 23S12. The NHTSA Recall Number is 23V162. The https://www.nhtsa.gov/recalls website instructed me to file an online complaint if the manufacturer has failed or is unable to remedy this safety recall for your vehicle in a timely manner.

NHTSA complaint #11591654 — an unverified report by a vehicle owner.

SERVICE BRAKES

The previous 2 models of this car had a recall on the button underneath the brake switch that is engaged by the pedal. They have not changed the design and the 2016 has the very same issue, plus another issue. We were able to replace the button ourselves since they decided not to admit that they did not change these parts even though they knew this was an issue years prior. Not only that, but the holder for the switch is part of the entire pedal assembly and it is the only part of this assembly that is made of plastic. The rest is metal. The problem is that since this is plastic, and it resides where the heat comes out from under the dash, the part becomes brittle and breaks into a million pieces just with normal wear. The pedal assembly is super expensive and you can't even get it out without removing the entire dash. We tried to get a used part and spent half of the day taking the part out only to find that it had done the exact same thing that my daughter's car did. The plastic disintegrates and falls apart. At that point there is no brake switch and the brake lights stay on and the car will decrease speed without warning or won't accelerate. This is something I am pretty sure Ford is well aware of since they recalled part of this defective design years ago. They just didn't admit that the entire thing is designed to fail. It is only a matter of time due to the constant heat that the plastic holder for the brake switch is on. All they had to do was change it to metal and it would have fixed that part of the issue, but then there is also the button itself that disintegrates due to the same heat exposure causing the symptoms listed above. They knew very well the design was flawed since the 2 previous years of this car were recalled for the same issue, and they are still using the same parts in the exact same way. They have not fixed anything and this company needs to be held accountable before someone gets hurt.

NHTSA complaint #11591380 — an unverified report by a vehicle owner.

SERVICE BRAKES

I have contacted Flagship Ford Carolina in Puerto Rico in regard to processing my recall and continue to be pushed aside. For over a month now, I am told someone will call me back and never does or I am transferred and receive no response. When I call back week after week, it is the same situation over and over with someone different. One person has told me they work on this recall but have to confirm if parts are available and that someone will get back to me. It has been two weeks since. I have to ship my car back to the states in less than two weeks, and the recall is supposed to be completed. This is unacceptable. Their information is below. Flagship Ford Carolina Ford dealer in Carolina, Puerto Rico Address: Parque Escorial, Av. 65 de Infantería KM 5.3, Carolina, 00984, Puerto Rico +1 787-302-2723

NHTSA complaint #11587246 — an unverified report by a vehicle owner.