4,041 of the
28,743 complaints filed about the Ford Fusion
are about the engine —
14% of everything owners reported.
The worst model year for it is 2010.
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.
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.
The vehicle in question has the coolant intrusion into cylinders 2 and 3 with rough idle on startup, P0300, P0302, P0303, and white smoke on startup. The vehicle now has 111339 miles on it and the out of pocket cost is more than what the vehicle blue books for in excellent condition. TSB 22-2134 speaks to all the issue and what the repair is. If this is a known issue then I feel this should be a vehicle recall by Ford due to the costly repair.
NHTSA complaint #11751941 — an unverified report by a vehicle owner.
There is a known coolant intrusion into the engine that caused the engine to suddenly only go to a certain speed while on the freeway. It could have caused an accident on the freeway by suddenly going at such a slow speed. It is now found out that the problem is known by Ford and is part of a technical service bulletin, but no recall has been issued on this known problem. The TSB associated are 19-2139, 19-2375, 20-2100. By not making this a recall, Ford is knowingly putting lives at risk with potential sudden loss of speed in these engines. It is lucky this was late at night when not many cars were on the road.
NHTSA complaint #11751875 — an unverified report by a vehicle owner.
While driving we noticed the engine light came on so we took it to our local mechanic. He said we were leaking coolant and it was too extensive fro him to fix so he suggested we put coolant in every few days. We researched the problem and found that these cars had a recall for this exact issue yet our VIN does not show it. We went to Ford Dealership and they confirmed we need a new engine as they connected the IDS. This vehicle was built at the Hermosillo plant, has the same 1.5L EcoBoost engine, and has experienced the exact coolant intrusion failure that Ford recalled or extended coverage for on other vehicles. I am asking Fotrd to reconsider my case because my vehicle has the identical defect despite my VIN not being included. My kids purchased this car for my wife and I in October 2025. I also included a VIN Report based on my VIN Number and if scroll to the bottom of that report maybe page 23 you will see the Recall.
NHTSA complaint #11750628 — an unverified report by a vehicle owner.
My backup camera often freezes after I shift from reverse to drive. The screen turns blue and at time will have a live video of me driving showing what’s behind my car. Also my engine loses power and doesn’t accelerate as it should. There is a powertrain and censor error that shows due to the Che k engine light being on. I had the issue fixed once at a ford dealer however the issue was not resolved. It started up again 48 hours later.I have noticed that all other ford fusions have the same two issues and were included in the recalls but the 2019’s are not ? Please assist I have been trying to have these issues resolved for years with no success.
NHTSA complaint #11750224 — an unverified report by a vehicle owner.
ENGINE HAS COOLANT INTRUSIONAND IS MISFIRING. Engine light came on. The coolant system found pressure to be dropping significantly. Removed spark plugs and inspected cylinder bores using borescope. Verified coolant is leaking into cylinder 2 and needed to replace the engine at Ourisman Ford in Manassas VA. on July 11, 2026.
NHTSA complaint #11749828 — an unverified report by a vehicle owner.
While driving at 75mph on the freeway, my 2020 Ford Fusion suffered a sudden, catastrophic EcoBoost engine coolant failure. The vehicle instantly lost power and dropped to 35mph in active traffic, creating an extreme highway collision hazard. A mechanic has confirmed internal coolant intrusion in the engine block.
NHTSA complaint #11749830 — an unverified report by a vehicle owner.
My 2013 Ford Fusion equipped with the 1.6L EcoBoost engine started blowing thick white smoke (Burning Coolant) while I was driving on the freeway. Engine coolant was leaking and my card died right there, that had blown the head gasket. I received no warning, no message. This was an incredibly dangerous situation because I was on the freeway and was forced to stop immediately. Ford Motor Company has refused to include my vehicle’s VIN in the applicable recall programs despite my vehicle experiencing the same issues described in NHTSA recalls 12V551000 (Ford Campaign 12S41) and 17V209 (Ford Campaign 17S09) The recalls identify issues involving coolant loss, overheating, insufficient warning of coolant loss, potential engine damage, cylinder head damage, and the risk of engine compartment fire. My vehicle exhibited these same symptoms and consequences which can be confirmed by the autobody shop where it was evaluated. The purpose of these recalls was to address a known safety concern involving the 1.6L EcoBoost engine cooling system. Despite this, when I contacted Ford and requested assistance and asked that my VIN be added to the recall population, Ford denied my request and stated that my vehicle was not included. I believe this decision fails to address the fact that my vehicle experienced the same defect and safety risk identified in the recall documents. The safety issue is not limited to the VINs currently listed in the recall population; rather, my vehicle demonstrates the same failure mode that prompted the recalls. My concern is that vehicles equipped with the same engine and experiencing the same defect may continue to pose a safety risk to drivers and passengers. A coolant loss event and overheating condition can result in significant engine damage, sudden loss of vehicle operation, costly repairs, and the potential for an engine compartment fire. respectfully request that this matter be reviewed and that Ford be required to re-evaluate their decision.
NHTSA complaint #11749772 — an unverified report by a vehicle owner.