4,053 of the
28,788 complaints filed about the Ford Fusion
are about the engine —
100% of everything owners reported.
The worst model year for it is 2010.
I am submitting this complaint regarding a serious engine failure and safety issue involving my 2017 Ford Fusion equipped with the 1.5L EcoBoost engine. At approximately 79,000 miles, my vehicle experienced a coolant intrusion failure. While driving, the engine suddenly stalled in the middle of an intersection, leaving me stranded in traffic and at risk of being rear-ended by approaching vehicles. I was able to restart the vehicle and move out of the intersection, but the exhaust then produced a very large, thick cloud of white smoke. The amount of smoke could have significantly reduced visibility for other drivers and created an additional safety hazard. I took the vehicle to a Ford dealership, where I was told the engine had coolant intrusion and needed to be replaced. I was also told this is a common problem with Ford EcoBoost engines, including the 1.5L, 2.0L, and 2.3L engines. My concern is not only the cost of the repair, but the serious safety risk. Coolant intrusion can cause misfires, excessive white smoke, engine damage, and eventual engine failure. A sudden loss of power while driving can create a serious crash hazard, as happened to me. I am concerned Ford has known about this recurring problem for years yet has continued using these engines in vehicles such as the Fusion, Escape, and Lincoln MKZ without adequately addressing the issue. I request that NHTSA investigate coolant intrusion affecting Ford EcoBoost engines and determine whether a safety defect exists that warrants a recall. I also believe affected owners should receive reimbursement for engine replacement costs when the failure is caused by this defect. My experience demonstrates that this is more than a normal maintenance issue. An engine that can suddenly stall in traffic and produce a large cloud of white smoke without warning poses a significant safety risk to vehicle occupants and other motorists.
NHTSA complaint #11763978 — an unverified report by a vehicle owner.
It all started with a cylinder 3 misfire warning code, spark plugs replaced, coils replaced. Then a coolant leak. No obvious signs of a leak no cracked tubing no puddles. Just coolant leaking. Was informed I have a coolant leak intrusion and need a new engine block. I still owe $14k on this vehicle and am past my warranty. This repair is going to cost $12k. Researched and found out this is a problem for these vehicles that ford had an engineering problem with these engines.
NHTSA complaint #11763139 — an unverified report by a vehicle owner.
Year/Make/Model: 2015 Ford Fusion Engine Type: 1.5L EcoBoost 4-Cylinder Description of Safety Flaw and Incident: My vehicle is experiencing severe overheating and internal engine fluid loss due to the widely documented Ford EcoBoost coolant intrusion defect. The vehicle routinely runs hot, losing coolant rapidly with no external signs of a visible hose or radiator leak as well as failure of the brake lighting stop bumper and purge valve connecting to the gasline after fueling. This issue causes the vehicle to rapidly overheat while in motion, forcing sudden loss of engine power (limp mode) during highway driving. Car not properly cranking after fueling and brake light continuously being on even when brakes not being pressed. This unexpected drop in speed creates an immediate crash hazard for myself and surrounding traffic. Coolant entering the combustion chamber also fouls the spark plugs, causing severe engine stalling, rough idling, and misfires. I've spent several dollars fixing these malfunctions that have continuously persist. Ford Motor Company has historically been aware of this structural defect involving coolant leaking across the cylinder bore walls, yet failed to issue a comprehensive safety recall for 2015 models. I am filing this complaint to urge the NHTSA to open a formal defect investigation and mandate a safety recall, as this component failure leaves drivers stranded in hazardous traffic situations.
NHTSA complaint #11762932 — an unverified report by a vehicle owner.
The contact owns a 2017 Ford Fusion. The contact stated that while driving 60 MPH, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The vehicle lost motive power, and the RPM became elevated. In addition, the contact became aware of an abnormal odor. The contact referenced an unknown recall; however, the VIN was not associated with a recall associated with the failure. The failure mileage was approximately 150,000.
NHTSA complaint #11762700 — an unverified report by a vehicle owner.
The contact owns a 2013 Ford Fusion. The contact stated that while stopped in a drive-thru, there was an abnormal hissing sound coming from the brake pedal. There was no warning light illuminated. The brake pedal was depressed to the floorboard, and excessive force was needed to stop the vehicle. The vehicle was driven to the residence. The contact stated that after restarting the vehicle, the "Check Engine" warning light was illuminated and the "Brake Level Low" message was displayed. The contact associated the failure with NHTSA Campaign Number: 23V162000 (Service Brakes, Hydraulic); but was unable to secure an appointment with two local dealers for a timely repair. The contact requested authorization to have the vehicle repaired by an independent mechanic with reimbursement, but the manufacturer declined the request. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer denied a request for a loaner vehicle. The contact was provided a case number. The vehicle was not repaired. The failure mileage was 172,318.
NHTSA complaint #11761586 — an unverified report by a vehicle owner.
The contact owns a 2018 Ford Fusion. The contact stated that the check engine warning light was illuminated. Additionally, there was white smoke coming from the exhaust pipes. The vehicle was taken to an independent mechanic several times, and the contact was informed that the engine was consuming antifreeze. The ignition coils and spark plugs were replaced; however, the failure persisted. The mechanic associated the failure with the engine. The vehicle was taken to a dealer, where it was diagnosed and determined that the short block was warped and that the engine needed to be replaced. The vehicle was scheduled to be repaired. The contact researched the failure and stated that it was a known issue that the manufacturer had failed to correct. The manufacturer was notified of the failure via telephone; however, no assistance was provided. The failure mileage was approximately 122,000.
NHTSA complaint #11761524 — an unverified report by a vehicle owner.
2017 Ford Fusion. Transmission replaced February 2026 at 98,175 miles by independent repair facility. Check engine light illuminated immediately following replacement and has remained on continuously since. Autozone scan showed emissions-related code only. On August 28, 2026 at approximately 120,064 miles, orange wrench light and "See Manual" message appeared moments after hot restart. Acceleration became heavy and hesitant. Drove approximately 70 miles home via I-15; heavy traffic required engine shutdown at multiple stops. Following morning, wrench light was no longer illuminated but hesitation persisted. Using manual paddle shift to select 5th gear improved drivability. Replacement transmission accumulated approximately 22,000 miles over 6 months. Ford Motor Company has issued multiple recalls for 2013-2016 model year Fusions involving identical transmission, shifter cable bushing, and torque converter defects, but 2017 model year vehicles with identical 6F35 transmissions and failure symptoms have been excluded from all campaigns. No crash, fire, or injury occurred.
NHTSA complaint #11760693 — an unverified report by a vehicle owner.
The 2015 ford fusion are very known for this issue with coolant lost and more recently I was driving and a warning popped up saying my coolant was over temps so I pulled over and turned the car off next thing you know my coolant was gone and I just filled it up. To make it even worse my mechanic told me it’s a known issue and ford doesn’t even cover it because it isn’t a recall
NHTSA complaint #11759737 — an unverified report by a vehicle owner.
We have coolant intrusion in cylinder 2 of our engine. This can cause highway failure of engine cuts out, car runs rough and it can become a fire hazard. We paid for a diagnostics through a ford dealer. Who we uses all the time for our warranty needs. We noticed car was starting to run rough and check engine light came on 8/5/26
NHTSA complaint #11759853 — an unverified report by a vehicle owner.
my 2018 ford fusion has catastrophic engine failure. Engine stuttering and misfires with check engine light. Low coolant levels with no visible puddles under the car. Engine overheating, could possibly catch fire. Car recently had a tuneup was told no issues at the time. Failure mileage at 109,000.
NHTSA complaint #11759398 — an unverified report by a vehicle owner.
While driving my Ford Fusion, I experienced a serious transmission-related loss of propulsion. Leading up to the failure, I noticed that the engine RPM would fluctuate considerably and the vehicle appeared to have difficulty maintaining engagement in a gear. On the day of the failure, I was traveling approximately 50 mph when the vehicle suddenly stopped responding normally to the accelerator. When I pressed the accelerator, the engine RPM increased significantly, but the vehicle would not accelerate accordingly. It appeared that engine power was no longer being properly transferred through the transmission to the wheels. I was only able to get the vehicle home in a severely reduced-performance/limp condition. The vehicle was also leaking fluid associated with this failure. I subsequently received an NHTSA recall alert for Recall 26V376, “Transmission Clutch May Fracture and Leak Fluid,” which includes certain Ford Fusion model years. The failure I experienced appears very similar to the condition described in this recall, particularly the loss of propulsion accompanied by increased engine RPM and the presence of a fluid leak. However, when I checked my VIN, I was informed that my vehicle is not currently included in the recall. I am submitting this safety complaint because my vehicle experienced what appears to be a substantially similar failure, including loss of propulsion while traveling approximately 50 mph and subsequent fluid leakage. I am requesting that NHTSA review my vehicle's failure in connection with Recall 26V376 and determine whether the affected vehicle population may need to be expanded.
NHTSA complaint #11759150 — an unverified report by a vehicle owner.
Vehicle blew upper radiator hose due to blown head gasket. Vehicle has trouble starting and releases grey blue smoke via exhaust at all times. Has not been looked at by anyone other than an odot employee and myself. Hose was replaced but issues continue. Vehicle engine light came on after low coolant warning and overheating. Vehicle is available for inspection. Google states this is an extremely common occurrence with this particular year and model of vehicle.
NHTSA complaint #11758036 — an unverified report by a vehicle owner.
If i do not run my car for atleast 10 minutes before driving, my gas tank will start making a loud horn sound, and when this happens and i go to slow down, the car will shut off. Mechanics say there’s an issue with the purge valve and the charcoal filter. I’ve already had this issue fixed three times and it comes back less than a week prior to service
NHTSA complaint #11757803 — an unverified report by a vehicle owner.
COMPONENT THAT FAILED: The engine cooling fan on my 2020 Ford Fusion SEL (1.5L, non-hybrid) became inoperable and blew three fuses. With the fans not operating, the engine overheated, destroying the head gasket and engine, requiring complete replacement. Failure occurred 07/08/2026 at 49,118 miles. WARNING SYMPTOMS: The A/C began blowing warm air roughly 2 days earlier. The engine temperature lamp illuminated on 07/08/2026 — the first and only time it ever came on. No prior overheating, no coolant loss, no leaks, no other alert. I stopped driving immediately on that single warning and had the vehicle towed. SAFETY RISK: A cooling fan failure progressing to engine destruction risks overheating, loss of motive power, and stalling in traffic or at highway speed. I stopped safely; a driver getting this same lone warning on a freeway would face a serious hazard with no notice. The vehicle's protections did not prevent a low-cost part from destroying the powertrain, and the sole warning came immediately before catastrophic damage. CONFIRMED BY INDEPENDENT SERVICE CENTERS: Yes. A certified technician at a licensed independent shop found the cooling fan assembly inoperable and identified it as the cause of both the A/C failure and the temperature warning, noting these vehicles are known to fail head gaskets this way. A second licensed engine shop documented the sequence: the electric cooling fan failed, which blew three fuses, causing an overheat condition that caused engine failure. Written findings, inspection reports, and invoices retained. MANUFACTURER INSPECTION: None. Ford declined to consider assistance unless a Ford technician inspected the vehicle, by which time it was already at an independent shop mid-repair. No police or insurance inspection. MANUFACTURER AWARENESS: Ford SSM 48659 covers 2019-2020 Fusion/MKZ non-hybrids with cooling fans inoperative due to open fuses F59, F60, F63, causing engine overheat or lack of A/C cooling.
NHTSA complaint #11757150 — an unverified report by a vehicle owner.
I am reporting a serious recurring safety concern involving a 2017 Ford Fusion SE with a 1.5L EcoBoost engine. The vehicle was purchased used in August 2022 with approximately 50,000 miles. Within months, significant coolant and engine problems began. In February 2023, at approximately 55,940 miles, the vehicle developed a coolant leak. A pressure test confirmed the water pump was leaking and it was replaced. At approximately 84,189 miles, the vehicle experienced white/gray exhaust smoke, coolant loss, very low oil, and rough-running symptoms. The servicing Ford dealership referenced Ford Technical Service Bulletin (TSB) 22-2322 in connection with the diagnosis and ultimately replaced the engine short block. Despite this major engine repair, the problems continued. The vehicle subsequently experienced additional smoking, hesitation and loss of power and required replacement of the turbocharger. The vehicle was returned again because it continued to smoke and required additional repairs. I am concerned this is a recurring engine defect rather than normal wear and tear. The repeated engine/coolant failures, smoking, hesitation and loss of power create a serious safety concern because the vehicle may unexpectedly lose power or experience engine failure while being driven. Ford has been notified of the repeated failures but declined further relief based primarily on the vehicle's current age, mileage and expired warranty. This ignores that the problems began years earlier at substantially lower mileage and that major repairs failed to permanently correct the condition. I request that NHTSA investigate whether the 1.5L EcoBoost engine in this and similarly equipped Ford vehicles has a safety-related defect involving coolant intrusion, engine failure and loss of power. The vehicle is currently at approximately 101,000 miles, but the documented problems began at 55,940 miles and continued despite major repairs.
NHTSA complaint #11756818 — an unverified report by a vehicle owner.
The 1.5L EcoBoost motor has coolant intrusion problem on cylinder 3. The 1.5L EcoBoost motor sputters while driving causing the engine to be sluggish and not get up to speed when turning and might cause an accident on the highway due to the motor failing due to coolant intrusion design flaw in Ford Motor. Yes, Ford dealership confirmed the coolant intrusion problem on cylinder 3 and check engine light keeps coming on and off. Yes, the Ford dealership inspected the 1.5L engine in the vehicle and ran test to confirm the coolant intrusion problem on cylinder 3. There was no other warning lamps or symptoms prior to the failure/degrade of engine
NHTSA complaint #11756448 — an unverified report by a vehicle owner.
I have a coolant intrusion into the engine and blew my engine in the middle of driving down the highway. No signs, no warning. Lost control, ended up on side of road. Had husband pull it the rest of the way home.
NHTSA complaint #11754348 — an unverified report by a vehicle owner.
The contact owns a 2013 Ford Fusion. The contact stated that while driving at an undisclosed speed, the low coolant warning light illuminated, and the vehicle stalled. The failure was a recurring failure. The contact associated the failure with NHTSA Campaign Number: 12V551000 (Engine and Engine Cooling); however, the VIN was not included. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was unknown.
NHTSA complaint #11753980 — an unverified report by a vehicle owner.