45 of the
2,075 complaints about the 2016 Ford Fusion are about the
wheels — 2% of everything
reported for this model year.
Half of the failures with a mileage on record happened before
50,212 miles.
Considering your experience of losing total control of the vehicle even while driving slowly while following a snowplow vehicle dispensing road deicer while plowing; I have a strong suspicion that his has happened in 2024 as well when the vehicle had registered a drive issue and the dealership found now existing reason for it. The compacted snow forms a large layer of snow and ice in the wheel wells to the point that it is rubbing on the tires all around the wheel wells. As this icy snow hardens while the vehicle is parked; it is dangerous to drive on any road surface in this condition at any speed. While the danger was less in the past due to not driving to Cass Lake, Minnesota from Bemidji, Minnesota and back nearly every other day; it has become critical this winter because of the high increase in winter snowy road driving that you are currently doing. Even though doing Hemo-Dyalisis at home decreases the danger; this vehicle is at risk of suddenly going out of control during winter snowing highway driving conditions if ice and snow builds up around the tires where it can suddenly release and jam tires from turning. You need to be aware of the danger you place yourself and other motorists in if you are driving this Ford Fusion Energi while in these dangerous driving conditions. In the past I have seen the condition of ice and snow buildup in the front and rear wheel wells to the point that there is less than one half inch of clearance between the tires and the ice/snow buildup. I did not allow you to drive it that way until I had chopped and removed it from around the tires and wheel wells.
NHTSA complaint #11708204 — an unverified report by a vehicle owner.
Monroe, LA
WHEELS:LUGS/NUTS/BOLTS/STUDS
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.
Bel Air, MDCrash
WHEELS
On [XXX], Plaintiff [XXX] was in urgent need of replacing the front passenger side tire on his vehicle. He began searching online to compare automotive service providers, focusing on those offering competitive pricing and professional-grade installation. During my search, 1 came across Mr. Tire's website, which prominently displayed claims such as "Expert installation for less" and "Quality service for superior stopping power." According to their site, their tire installation package included: • Tire mounting and wheel balancing • Standard valve stem replacement • TPMS inspection and reset • Wheel alignment check • Precision wheel torque by hand tools • Lifetime tire rotation • Lifetime rebalancing Believing this was a comprehensive and professional service package, I scheduled an appointment at Mr. Tire, located at 5 Bel Air South Parkway, Bel Air, MD 21014 (Store #771). Upon arrival, I checked in with the store manager, Brianna Adams, who prepared my service contract. She explained the total cost for installing the new tire would be $191.53. The technician assigned to my vehicle was J. Foster, as listed on the service agreement and receipt. On [XXX], while driving, I was involved in a serious accident. The front passenger side tire completely detached from the vehicle while in motion, causing the car to slam into the ground. I was severe risk of injury or death. The way I've taken this to court as / went back and looked at the reviews as of today's date October 18th 2025 they still are committee, consumer fraud, unsafe, work practices, deceptive business practices, and are putting the community and the residence of the state of Maryland and beyond at risk from unsafe work practices and I have submitted the reviews as a PDF as an attachment to this complaint I am requesting for investigation into their business for unsafe work practices and 49 U.S.C.§ 30101 (Purpose and policy)Maryland Transportation Code § 22-405 and § 21-101 INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552
NHTSA complaint #11695733 — an unverified report by a vehicle owner.
Sioux Falls, SD
WHEELS
Lug nuts are swollen and need replacement. Ford service department informed me that lug nuts are aluminum clad steel and over time swell and are unusable. Further informed that this is a common problem with ford products, but ford will not replace the lug nuts. Safety risk: Consumer would be unable to remove & reuse factory original lug nuts if a tire replacement were necessary away from a ford service facility. This condition is only diagnoseable when attempting to remove the lug nuts for service. I feel that any competent engineer could foresee that mixed metal will develop an electrolytic reaction and, further, that ford willingly continues this practice.
NHTSA complaint #11679417 — an unverified report by a vehicle owner.
Stamford, CT
WHEELS
Stamford Ford in Stamford CT said I need to replace frozen lug nuts due to corrosion. they said it is not covered and I have to absorb the cost of $ 300. All service on this vehicle have been performed by ford service department. a recall should have been issued to correct this issue. this is a safety issue and FORD must fix this at their cost, not the customer's.
NHTSA complaint #11565520 — an unverified report by a vehicle owner.
Stamford, CT
WHEELS:LUGS/NUTS/BOLTS/STUDS
Stamford Ford in Stamford CT said I need to replace frozen lug nuts due to corrosion. they said it is not covered and I have to absorb the cost of $ 300. All service on this vehicle have been performed by ford service department. a recall should have been issued to correct this issue. this is a safety issue and FORD must fix this at their cost, not the customer's.
NHTSA complaint #11565520 — an unverified report by a vehicle owner.
Millington, TN
WHEELS
Ford Dealership is refusing to preform the brake line recall 23S12, if I do not purchase new lug nuts saying that they are swollen, deformed. I called the corporates number and they told me they are aware of the issues with the lug nuts, but also said I would have to pay out of pocket for them to preform the brake line recall. I'm now worried about the condition of the lug nuts since the hold they wheel on as well as the brake line in the above mentioned recall which they are refusing to service without taking payment over a recall !!!
NHTSA complaint #11557427 — an unverified report by a vehicle owner.
at 120,000 milesMillington, TN
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2016 Ford Fusion. The contact stated that upon taking the vehicle to the dealer for service, he was made aware that the driver’s and passenger’s side front wheel lug nuts were severely deformed. As a result, the dealer declined to complete the service due to safety concerns. The vehicle was not repaired. The manufacturer was notified of the failure but did not assist. The failure mileage was 120,000. The VIN was not available.
NHTSA complaint #11557437 — an unverified report by a vehicle owner.
at 22,545 milesSevierville, TN
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2016 Ford Fusion. The contact stated that the vehicle was at the dealer for a scheduled service appointment; however, the service could not be completed because the bolts were swollen. The contact was informed that the bolts for all four wheels needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to report the failure to the NHTSA Hotline. The failure mileage was approximately 22,545.
NHTSA complaint #11552024 — an unverified report by a vehicle owner.
Apple Valley, MN
WHEELS
the lug nuts had swollen and were not able to loose without damage. In order to rotate my tires the dealership had me pay for new lug nuts. If they the parts were that cheaply made at the factory, why am i asked to pay for them.
NHTSA complaint #11533694 — an unverified report by a vehicle owner.
Mobile AL, AL
WHEELS
Lug wrenches don't go on lugs. Can't remove lugs.
NHTSA complaint #11528721 — an unverified report by a vehicle owner.
Marietta, GA
WHEELS
I took my car for tires to be rotated and balanced. The LUG NUTS are swollen because of the metal they're made from. I will have to PAY for new lug nuts which are the exact same lug nuts as are on my car - and the same thing will happen again - and I'll have to PAY AGAIN. This is outrageous. Ford should have a recall for all affected vehicles. We have a 1999 vehicle and the lug nuts are in excellent shape.
NHTSA complaint #11522662 — an unverified report by a vehicle owner.
Waverly, NY
WHEELS
I was at the ford garage and they told me my lug nuts are swollen! Which can be very hazardous!!!
NHTSA complaint #11522089 — an unverified report by a vehicle owner.
at 40,000 milesVirginia Beach, VA
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2016 Ford Fusion. The contact stated that while the tires were being replaced, the dealer informed the contact that the lug bolts were swollen. Additionally, the dealer stated that if the lug bolts were removed, the bolts would be stripped and would need to be replaced. The lug bolts were not replaced. The manufacturer was not made aware of the failure. The failure mileage was approximately 40,000.
NHTSA complaint #11517627 — an unverified report by a vehicle owner.
Alameda, CA
WHEELS
I had a flat tire. When I went to get the lug nut wrench it was not there. Since this was the first time that I removed the spare tire and the lug nut wrench was not there it appears as though the car never came with one. I called AAA and they had to destroy the outer coating of the lug nut in order to remove it as it seemed to have swollen 1/2 size. I took the car to my service provider and he said that all of the lug nuts were the same and no wrench would fit them. I had to have all lug nuts replaced with ones the correct size and I had to buy a new Lug Wrench to make up for the one I never got. The total cost was $337.02 which I would like Ford to compensate me for.
NHTSA complaint #11498555 — an unverified report by a vehicle owner.
Alameda, CA
WHEELS:LUGS/NUTS/BOLTS/STUDS
I had a flat tire. When I went to get the lug nut wrench it was not there. Since this was the first time that I removed the spare tire and the lug nut wrench was not there it appears as though the car never came with one. I called AAA and they had to destroy the outer coating of the lug nut in order to remove it as it seemed to have swollen 1/2 size. I took the car to my service provider and he said that all of the lug nuts were the same and no wrench would fit them. I had to have all lug nuts replaced with ones the correct size and I had to buy a new Lug Wrench to make up for the one I never got. The total cost was $337.02 which I would like Ford to compensate me for.
NHTSA complaint #11498555 — an unverified report by a vehicle owner.
Atlanta, GA
WHEELS
Lug nut shattered and unable to remove the nut to safely replace
NHTSA complaint #11487106 — an unverified report by a vehicle owner.
Leon, KS
WHEELS
I went to get oil changed and tires rotated. Expected to just pay for that. However, was told my lug nuts were swollen and ended up having to get them replaced as a safety issue. I have never heard of this issue before. I only have 50,000 miles on my car. I am retired, an have fixed income. Therefore, the price of $120 plus tax put quite the dent in my grocery allowance. This should be a recall. And all that have experienced this should be reimbursed. I have been a Ford owner all my life, but next car will be asking more questions about the lug nuts. Can't afford to do this every 4 or 5 years.
NHTSA complaint #11476099 — an unverified report by a vehicle owner.
Salisbury, NC
WHEELS:LUGS/NUTS/BOLTS/STUDS
Lug nuts are swelling and tires will not come off.
NHTSA complaint #11475296 — an unverified report by a vehicle owner.
Victoria, TX
WHEELS
Lug nuts were impossible to remove as the wrench supplied by Ford would NOT engage the nut. WE spent two hours on side of a busy highway at risk while several people tried to remove the nuts. Finally, the tech from towing service had to beat the wrench onto each nut, destroying the outer shell in each case. After two hours in the Texas heat, spare was attached and we replaced ALL the nuts for $48 plus tax. VERY ALARMING SITUATION as we often travel on remote roads and areas.
NHTSA complaint #11472090 — an unverified report by a vehicle owner.
Kansas City, MO
WHEELS:LUGS/NUTS/BOLTS/STUDS
Lug nuts swollen and were unable to be removed.
NHTSA complaint #11466560 — an unverified report by a vehicle owner.
at 44,010 milesDorchester Center, MA
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2016 Ford Fusion. The contact stated that the lug nuts were swollen and were unable to be removed. The vehicle was taken to the local dealer and the contact was informed that there was a defect with the lug nuts. The vehicle was repaired however, the failure recurred. The vehicle was taken to the same dealer for tire rotation and the contact was informed that the lug nuts were swollen. The contact declined the repairs. The manufacturer was notified of the failure and referred the contact to NHTSA but, provided no further assistance. The approximate failure mileage was 44,010.
NHTSA complaint #11443901 — an unverified report by a vehicle owner.
Hammond, LA
WHEELS
When I took my car in for service, I was told that my lug nuts were swollen and had to be replaced.
NHTSA complaint #11443117 — an unverified report by a vehicle owner.
Laguna Niguel, CA
WHEELS:LUGS/NUTS/BOLTS/STUDS
Distorted lug nuts
NHTSA complaint #11441302 — an unverified report by a vehicle owner.
Dallas, TX
WHEELS
Lug nuts expand in hot climate and cannot be removed by owner. Discount Tire had to remove. I replaced them all, for $55, so there is no future problem.
NHTSA complaint #11436467 — an unverified report by a vehicle owner.
at 50,000 milesFort Thomas, KY
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2016 Ford Fusion. The contact stated while having an oil change performed at an independent mechanic, she was informed that the lug nuts were swollen. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 50,000.
NHTSA complaint #11433059 — an unverified report by a vehicle owner.
at 53,000 milesBethlehem, PA
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2016 Ford Fusion. The contact stated that all four lug nuts were swollen. The contact stated while having a tire replacement by a towing company, the driver was made aware that there was an issue with removing the lug nuts. The vehicle was towed to the local dealer and the contact was informed to contact the manufacturer for assistance. The manufacturer was notified of the failure and referred the contact to the NHTSA. The failure mileage was 53,000.
NHTSA complaint #11431259 — an unverified report by a vehicle owner.
at 67,490 milesDecatur, GA
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2016 Ford Fusion. The contact stated that the factory lug nuts were swollen and difficult to remove the tires when needed. The contact had not spoken with a dealer nor a certified mechanic. The contact intended on replacing the lug nuts replaced with a better-recommended type. The vehicle was not repaired. The manufacturer was made aware of the issue. The approximate failure mileage was 67,490.
NHTSA complaint #11423133 — an unverified report by a vehicle owner.
at 60,000 milesManchester, CT
WHEELS
HELLO, I HAVE A 2016 FORD FUSION. I BOUGHT IT IN 2019 FROM A BIG LOCAL CAR DEALER. I BROUGHT IT IN TO A FORD DEALER ON 4/16 FOR ROUTINE SERVICE. THE SERVICE PERSON CALLED ME AFTER I DROPPED OFF THE CAR TO TELL ME THAT MY FUSION HAS "SWOLLEN LUG NUTS" AND IT WOULD COST ME $164 FOR ALL NEW LUG NUTS AND LABOR COSTS. I HAD NO REAL CHOICE AND HAD TO PAY. SUBSEQUENTLY I HAVE DONE SOME RESEARCH AND HAVE FOUND THAT "SWOLLEN LUG NUTS" HAVE BEEN A MAJOR PROBLEM FOR SOME FORD OWNERS LIKE ME. FOR SOME UNKNOWN REASON TO ME MY FORD DEALER SAID THERE HAS NOT BEEN A RECALL EVEN THOUGH THIS IS A COMMON ISSUE FOR THEIR CUSTOMERS. THANKFULLY I WAS AT THE FORD DEALER FOR ROUTINE SERVICE RATHER THAN HAVING A FLAT TIRE ON AN INTERSTATE. I CONTACTED FORD AND ESSENTIALLY I WAS TOLD TO SAVE THE RECEIPT IF THERE EVER IS A RECALL AND THAT WOULD EMAIL FORD ENGINEERS OF MY ISSUE. I BELIEVE THIS TO BE A SERIOUS SAFETY ISSUE. CAN YOU HELP? THANK YOU
NHTSA complaint #11413027 — an unverified report by a vehicle owner.
at 53,646 milesHobart, IN
WHEELS
WHEN I BROUGHT THE CAR IN TO HAVE NEW TIRES INSTALLED, I WAS INFORMED THAT THE LUG NUTS WERE SWOLLEN DUE TO A DESIGN FLAW AND COULD NOT BE USED. I HAD TO PURCHASE NEW LUG NUTS BEFORE THE TIRES COULD BE INSTALLED. I WAS TOLD THAT THE LUG NUTS COULD NOT BE PUT BACK ON THE CAR BECAUSE IT WOULD CAUSE A SAFETY ISSUE, AS THE TOOL USED TO REMOVE THEM WOULD NOT FIT IN THE CASE OF A FLAT TIRE OR THE CAP MAY COME LOOSE AND CAUSE THE LUG NUT TO BECOME LOOSE AND CAUSE THE TIRE TO FALL OFF THE VEHICLE.
NHTSA complaint #11403148 — an unverified report by a vehicle owner.