431 of the 28,743 complaints filed about the Ford Fusion are about the wheels — 1% of everything owners reported. The worst model year for it is 2010.
431
Complaints
1%
Share of all complaints
22
Crashes
0
Fires
WHEELS
Lug studs keep breaking off while driving
NHTSA complaint #11749185 — an unverified report by a vehicle owner.
WHEELS
Ford's double-capped acorn lug nuts experienced outer cap expansion/separation during an emergency roadside tire change. A defective design known by Ford. Rendering the supplied tire iron and a separately purchased multisize tire iron ineffective at removing the lugs. The failure left the vehicle immobile on the side of a i75 in SWFL in the summer heat of June 2026. Present in the vehicle were the owner, spouse, and a [XXX] infant. They were stranded approximately 34 miles from home for nearly 3 hours, an extended period for a XXX, who quickly became visibly distressed. Standard FDOT Road Ranger assistance was unavailable, and towing services had estimated wait times exceeding 2 hours. The driver was unable to resolve the situation through any reasonable self-help measure due to the defective lugs, despite having successfully changed tires on the same vehicle previously using the same factory equipment. The defect was verbally identified during the incident by a responding AAA roadside technician. They recognized the defect as consistent with a known issue affecting Ford vehicles. No formal inspection by Ford Motor Company, law enforcement, or insurance representatives has taken place but will be pursued by the owner and available for inspection is requested. No warning lamps, dashboard alerts, or observable symptoms were present that would have indicated a lug nut defect to the owner. It only became apparent at the moment an emergency tire change was required. This is consistent with prior reported cases and litigation involving Ford. The owner was never informed of this defect during the vehicle purchase, service history, or extended warranty agreement. If known road side assistance would have been contacted, instead of self servicing the tire change which was rendered useless by a defect Ford has been aware of. Resulting in nearly 3 hours of preventable roadside exposure, emotional distress, and the endangerment of a [XXX] infant. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C.
NHTSA complaint #11743999 — an unverified report by a vehicle owner.
WHEELS
The front left lower control arm (driver's side) snapped off (broke) while turning a corner. There was no reason for the breakage other than turning. It was repaired through insurance. The driver's safety as well as the safety of pedestrians were put at risk because the breakage forced the car to turn sharply to the left. Because of this, the vehicle struck a utility pole. The pole had very little damage, but damage was done to the car. The policeman at the scene inspected the damage, as well as the insurance adjuster in the days following the accident. No warning lights or messages were displayed before the control arm broke. If this had happened at hi-way speeds, it is likely that the resulting loss of control would have resulted in a multi-vehicle accident, resulting in fatalities.
NHTSA complaint #11734895 — an unverified report by a vehicle owner.
WHEELS
We were made aware of Recall 11V574000 by our automotive shop, which applies to lugs/nuts/bolts on 2010 Ford Fusions, but only starting with manufacturer dates April 2009. This vehicle is dated February 2009, but we have replaced lugs/nuts/bolts at least 6 times in the past 5 years, clearly having the same problem. It has been an expensive, constantly reoccurring problem.
NHTSA complaint #11734661 — an unverified report by a vehicle owner.
WHEELS
Complete loss of power steering while driving, Service Power Steering Now warning light came on right after, service advance trac warning right after that. After doing some research this is a known issue to Ford and customer service agent confirmed this in chat, screenshot included.
NHTSA complaint #11719026 — an unverified report by a vehicle owner.
WHEELS
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.
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.
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.
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2011 Ford Fusion. The contact stated that while operating the vehicle, the message "Power Steering Sensor Fault" was displayed, and the steering wheel became difficult to turn in either direction. Additionally, while depressing the brake pedal, the vehicle was shaking and vibrating abnormally. The cause of the failure was not yet determined. The manufacturer was notified of the failure, but no assistance was offered. The contact stated that while attempting to rotate the tires, the lug bolts fractured and needed to be replaced. The failure mileage was 170,000.
NHTSA complaint #11689523 — an unverified report by a vehicle owner.
WHEELS
1. After vehicle is given gas it won’t crank. 2. Tire sensors won’t turn off. Even with brand new tires and mounts. 3. Random electrical malfunctions. (Flickering dash lights, delayed engine start after turning the key, light bouncing back and forth between gears, etc.)
NHTSA complaint #11682758 — an unverified report by a vehicle owner.
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2010 Ford Fusion. The contact stated that while the vehicle was parked, the wheel studs on the front passenger’s wheel detached from the wheel. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for further assistance. The failure mileage was approximately 61,000.
NHTSA complaint #11680875 — an unverified report by a vehicle owner.
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.
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2011 Ford Fusion. The contact stated while driving 25 MPH, the front driver's side wheel lug nuts fractured, causing the wheel to detach and the vehicle to shudder. The contact decelerated to 15 MPH, and the vehicle stopped. The driver and the two children that were occupying the vehicle had not sustained any injuries. There were no warning lights illuminated. The contact related the failure to NHTSA Campaign Number: 11V574000 (Wheels). The contact called the local dealer, who confirmed that the VIN was not included in the recall. Additionally, the contact was informed that the recall covered steel rims however, the vehicle was equipped with aluminum rims. The vehicle was not diagnosed or repaired. The vehicle was towed to an independent mechanic, who contacted the local dealer to confirm the recall details. The manufacturer was contacted and referred the contact to the NHTSA Hotline for assistance. The failure mileage was unknown.
NHTSA complaint #11678143 — an unverified report by a vehicle owner.
WHEELS
Tuve un Choque mi carro no freno y Choque a un carro que iba a dar vuelta a la izquierda, frene y mi carro no lo hizo , el impacto fue el que freno , mi carro se dano todo el frente , el punto es que yo lleve mi carro a remplazar las bolsas de aire al dealer , hace como 7 messes que porque estaban defectuosas ,, a mi carro no le hicieron ningun cambio de bolsas de aire solo las desconectaron , y al dia siguiente me prende en el tablero el foco De la bolsa de aire .no debieron desconectar eso no fue lo que me dijeron a mi
NHTSA complaint #11665852 — an unverified report by a vehicle owner.
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2012 Ford Fusion. The contact stated that while his son was driving at 65 MPH, he had to pull over to the side of the road due to a flat tire. The contact's son had a difficult time removing the lug nuts. The lug nuts could not be removed with the tire iron. The contact called AAA, and it was difficult for the Roadside Assistant to remove the lug nuts. The contact was informed that the lug nuts were swollen due to the aluminum or chrome material. The contact stated that the Roadside Assistant had to drill the lug nuts to remove the lug nuts. The vehicle was not repaired. The manufacturer was made aware of the failure but offered no assistance. The failure mileage was unknown.
NHTSA complaint #11665808 — an unverified report by a vehicle owner.
WHEELS
Power steering rack and pinion
NHTSA complaint #11656669 — an unverified report by a vehicle owner.
WHEELS
To keep it short. This is 1 of 3 Ford vehicles that I had to pay to have every lug nut replaced! They are 'swollen' is the term used. Prior to this, I replaced 1 lug in my 45 year driving history and that was because it broke off. I have called Ford and Lincoln and they are aware of the problem but say there is not program in place for a resolution. My complaint was escalated I was told. Hahaha. Their hand needs to be forced. They are not going to willingly do the right thing going forward nor address refunds! They have 'escalated' all 3 of my issues. I would imagine that there is a fourth coming at some point when my daughters car needs to go into the shop. $250+ a car is a joke and an expense nobody needs. Please help. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11652322 — an unverified report by a vehicle owner.
WHEELS
My steering wheel keeps locking up after I had the air bag recall taken care of
NHTSA complaint #11638608 — an unverified report by a vehicle owner.
WHEELS
We are the owners of a 2014 Ford Fusion model vehicle. We took this vehicle to a local Ford service dealer to have the tires rotated. Dealer service manager told us they could not do the tire rotate because the chrome plating on the wheel lug nuts had swollen and their wrench would not fit the lug nuts. The offered non OEM replacement lugs nuts for our cost of $134.95 plus tax. I believe this is a safety issue as we could be stranded along any roadway should we have a flat tire needing us to use our spare, and unable to remove the flat tire. Our vehicle has a total of about 60,813 miles shown on the odometer. Apparently this swollen lug nut issue is a known problem with this vehicle? Can you help us resolve this?
NHTSA complaint #11623994 — an unverified report by a vehicle owner.
WHEELS:LUGS/NUTS/BOLTS/STUDS
The contact owns a 2015 Ford Fusion. The contact stated while the vehicle was at the dealer for a scheduled tire rotation, the contact was informed that the lug nuts were swollen. The contact was informed that the lug nuts needed to be replaced. The vehicle was repaired. The contact stated that a torch was used to remove the lug nuts. In addition, the contact was informed that the failure was a known issue. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 40,000.
NHTSA complaint #11622758 — an unverified report by a vehicle owner.