What 2,604 owners told NHTSA about the 2012 Ford Fusion Hev

Slippery/snowy conditions, applied brakes approaching a stop sign. ABS kicked in and brake pedal dropped to the floor. With reduced braking ability. This has continued since. This has happened the past 2 winters and will eventually just release and the brakes function normally, until the ABS is needed and then the same thing happens.

NHTSA ODI 11493496

There is intermittent failure when brakes are applied. Periodically when we push the brakes they go all the way to the floor and the car keeps moving forward and not brake. I have researched this and it seems Ford has recalled some of the ABS components in this model of car but not for this year/VIN.

NHTSA ODI 11488650

Shortly after a having the rear brake pads replaced, I noticed that the handbrake (or e-brake) would lose tension over night, but not always. Since this was occasional, then it appeared to be a hydraulic issue. About three months later (9/15/22), the brake pedal stopped working correctly and the pedal had to travel further, and be pushed to the floor to bring the car to a gradual stop. I almost went into the back of another vehicle, it's fortunate that I was travelling at a low speed when the brake failed. I took the vehicle to my Ford dealer/service shop and, following their inspection and diagnostic assessment, was told that there is a problem with the hydraulic control unit (HCU), and that the it would need to be replaced and the lines flushed. My vehicle is a 2012 Fusion. This sounds like the same HCU problem that lead to the recall for 2006-2010 Ford Fusion vehicles - refer Ford Motor Company (Ford) Recall No. 19S54 - https://static.nhtsa.gov/odi/rcl/2019/RMISC-19V904-0442.pdf Per linked pdf, the NHTSA opened EA18-002 and included inquiry of 2006-2012 Fords Fusion vehicles. It appears that only the older 2006-2010 models were included in the recall. However, as the newer (2012) models reach a similar mileage or age, it may worth reevaluating and extending the scope of the recall in the interest of safety for the traveling public. Had the brake failed while traveling a higher speed, then my life, my children's lives and others would have been at risk.

NHTSA ODI 11485479

The contact owns a 2012 Ford Fusion. The contact stated while driving approximately 30 MPH, the brake pedal was depressed but the vehicle failed to stop before the pedal went to the floorboard. The contact stated no warning light was illuminated. The contact took the vehicle to an independent mechanic who determined that the brake pads needed to be replaced. Additionally, the hydraulic system was bled. The contact stated that the failure reoccurred and the vehicle was driven to a dealer where it was diagnosed and determined that the hydraulic control unit (HCU) needed to be replaced. The contact was advised that the parts were on backorder. The contact was advised that the failure was related to NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic) however, the VIN was not included. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 165,000.

NHTSA ODI 11482466

Approximately three months ago the ABS system engaged due to applying my brake to avoid pedestrian crossing in front of me. After continuing to drive the brake pedal was very soft and traveled nearly to the floor of the car. The next day the system returned to normal. Several days ago, on 6/25/2022 this occurred once more when a hard brake was needed to avoid a suddenly stopped vehicle and the same problem became present with a soft petal and having to pump the pedal, my wife was the operator this time. The vehicle has not yet been inspected by any entity. I have inquired about this problem from my mechanic and also have researched the problem and see there is a recall > 19S54 also an update to the recall > EA18-002 that states my 2012 Fusion is included in the recall and will now contact the local Ford Dealership to have this concern corrected. In my research I see that is due to the ABS module sticking due to corrosion from the wrong brake fluid. I have had several close calls while operating my car, the recall states Ford advises it is safe to drive. This I strongly disagree with, particularly since my wife uses this vehicle and is not as skillful as I when it comes to mechanical issues such as this. There were no warning lights, or messages, the issue has now cleared up again and brakes are operating normally as before this incident. This vehicle is readily available for inspection on request.

NHTSA ODI 11472071

The contact owns a 2012 Ford Fusion. The contact stated while driving on the highway at an undisclosed speed and depressing the brake pedal, the pedal went to the floorboard. There were no warning lights illuminated. The contact was able to pull off the highway and the vehicle rolled to a stop. The vehicle was not taken to a dealer or independent mechanic to be diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 120,000.

NHTSA ODI 11471328

The contact owns a 2012 Ford Fusion. The contact stated while driving 20 MPH and depressing the brake pedal, the vehicle failed to stop within a reasonable time. The contact stated no warning light was illuminated. The contact stated he was able to stop the vehicle after pumping the brake pedal. The contact took the vehicle to the local dealer however, the mechanic was unable to duplicate the failure. The contact continued to experience the failure. The contact took the vehicle back to the local dealer, where it was diagnosed and the brake lines were flushed several times. The vehicle continued to experience the failure. The contact took the vehicle back for the third time and was informed that the rear and front brake calipers, the ABS hydraulic control unit (HCU), and the brake master cylinder needed to be replaced. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 95,000.

NHTSA ODI 11468604

After Replacing some Calipers, Rotors & Pads I took My vehicle to Meineke Car Care Center in Lawrence, Indiana to have the Brake system Flushed ("Bled") I got my car back and immediately after pulling off I had NO PEDAL! ALMOST GOING THROUGH A FENCE! My Hand Brake saving me intime. I declined to have it reserviced at Meineke and had it looked at by a Local Mechanic I trust. He informed me After Bleeding the Master Cylinder, ABS Module with a Scan Tool and All Calipers that there was still no pedal. Which meant one thing The HCU on the ABS Module is Bad. Which was likely because 2006-2010 Models of the Ford Fusion have a Recall on the ABS/HCU for Loss of Brakes. WHY THE 2012 MODELS DO NOT HAVE A RECALL ASWELL IS BEYOND ME? Even though the 2012 Model Shares ALOT of Key components with the previous year's models. Including the ABS/HCU. Why is the 2012 not included? Obviously Corporations, Federal Regulators & Insurance companys in Kahoots to dampen the blow back to the Automotive industry AT THE EXPENSE OF PEOPLES LIVES!!! DO THE RIGHT THING

NHTSA ODI 11455180

After starting the car, the brakes were not working properly--it required a lot of pressure to get the brake pedal to work. The brake light also came on indicating a problem with the ABS. After turning the car off and restarting it, the brakes worked fine again. The same thing happened the next day. That's when we took it for repairs. Our mechanic advised us to take it to a Ford dealer. Santa Monica Ford told us the ABS module and HCU need to be replaced at a cost of $2800 (and because there are delays getting the parts from Ford, it will take at least a couple of weeks). There is a related recall on Ford Fusions up to 2010, NHTSA campaign number: 19v904000 (service brakes, hydraulic). After some research, it's apparent that this is a common problem for Ford Fusion 2011 and 2012 models as well. It looks like the problem extends through 2012 and the recall should apply to those model years as well.

NHTSA ODI 11454557

Started car and began to back out of parking space. There had been a few drops of rain, but it wasn't actively raining at the time. Brake went to floor when driver went to slow down. Numerous dashboard lights and messages came on, including ABS, Traction Control, Traction Control Off, and "Service ADVANCETRAC" message. Driver stopped car with handbrake and shut car off. Tried several times to restart vehicle over the next 30 minutes, but lights remained on and brake remained soft. Finally restarted car and brake was normal, but lights remained on. All lights went on and car returned to normal when put in drive gear. This has happened about five times to two different drivers over the past 18 months. All but one time in rain, and twice while driving at 35 mph or so. We will plan to scrap or trade in the vehicle. Vehicle has been checked out by both an independent mechanic and Richmond Ford West, with no issues identified when examined.

NHTSA ODI 11450772

On October 5th, 2021 around 6:20am, the brakes on my 2012 Ford Fusion Hybrid failed to slow the car in any way. This event occurred while I was on the highway (M14) going ~65mph. Unable to conventionally stop, I was a crash hazard to those around me, and to the braking traffic in front of me. After being inspected by the Varsity Ford Dealership, I was told "the brake control unit is not actuating the valves in the hydraulic control unit" and that "there is a possibility that it will also need the hydraulic control unit as well." It has been at the dealership for the past 2 weeks and is available for inspection. There were no warning messages or signs prior to the brake failing. I received a warning sign at the point of failure, but by then I already knew the brakes did not work.

NHTSA ODI 11437970

I have a 2012 Ford Fusion and my breaks went out I replaced the master Cylinder in it as well as the brake booster and still didn’t have any brakes. While driving I couldn’t stop my Car had to go off to a ditch thankful that I didn’t have a accident I’ve been told that the ABS module might be the problem this should be a recall on this problem.

NHTSA ODI 11436538

On 08/07/2021 at approximately 3 pm while driving the vehicle low brake fluid level light indicated on dashboard. Stopped at a gas station and checked to make sure there was no brake fluid leaking and checked brake fluid level which was low. The cars brakes were still operating properly and we returned to the location we were staying to find an auto parts store to purchase brake fluid. At 6 pm, drove to the auto parts store to get brake fluid. We purchased the appropriate fluid and topped of the brake fluid reservoir. The low brake fluid light turned off on the dash after topping off the brake fluid. About 2 ounces were added. Upon leaving the auto parts store, we pulled out onto the road and when trying to brake, the brakes malfunctioned, the pedal went completely to the floor and the car did not stop normally and hit another vehicle. Police report attached. No injuries and minor damage to both vehicles bumpers Car was pulled off the road and was towed to shop for inspection as the brakes would not stop the car. Shop #1 replaced the master cylinder and the brakes still did not operate properly. Car was towed to shop #2 (Ford Dealer) and they diagnosed it as a failed ABS HCU unit in the vehicle that was not communicating with the onboard computer system. ABS HCU was replaced by the Ford Dealer and vehicle is now braking as normal. There were no warnings from the vehicle computer system that there were any issues with the brakes other than the low brake fluid level light, which was resolved by adding brake fluid. The 2006-2010 Ford Fusions have a recall for the ABS-HCU unit, but the recall did not include the 2011 and 2012 Ford Fusions, even though it appears to be the same ABS HCU unit. Upon doing research on the internet, this is a common problem with this year of Ford Fusion and there are no warnings or indications that this may occur. I feel the vehicle should be recalled and the brakes fixed.

NHTSA ODI 11432556

A few weeks ago I went to slow to a stop at the end of my driveway at approximately 5mph. My brake pedal dropped to the floor and i had to repress on the brake pedal to come to a complete stop. It continued working properly for a week or so when it happened again. The same week I was backing out of another driveway slightly down hill and attempted to come to a complete stop to look for traffic. Luckily there was none because my stopping distance was around 12 ft or so going maybe 3mph with the brakes completely pressed. I have since had my brake pads changed and all other components checked and was told were working properly. Now my stopping distance at 10mph is at least 3-4ft. I am too afraid to drive my vehicle at higher speeds on any road due to the stopping distance issues.

NHTSA ODI 11424293

While Driving my 2012 Ford Fusion like any other day… As approaching a 4-way intersection my traffic light was changing to red. When I went to stop using my brakes, my car would not stop at all and went completely through the intersection, and oncoming cars at each directions we’re coming towards me and my children. The brakes were as if they were not there and went completely to the floor and would not or did not stop my car at all. After several times pumping the brakes and strongly engaging in pulling the emergency brake numerous times I finally got my car to somewhat stop. This was the scariest thing I have ever experienced. Most definitely the most dangerous thing I have ever experienced my entire life for myself and my young children. We are truly lucky to be alive from these brakes completely, and unexpectedly spur of the moment going out! No warning!!! Models 2006-2010 Ford Fusions have a recall on this same exact brake system and have the same exact problem with the braking system unexpectedly and dangerously going out!!! Please get the recall extended on past 2010 and include 2011 and 2012 Ford Fusions!!! As they have the same exact braking systems!!!

NHTSA ODI 11422134

1) Brake Hydraulic Control Unit (HCU) failure. Dealership removed and replaced HCU assembly and ABS module. All parts retained by Dealer. 2) HCU brake failure made stopping very difficult and slow to stop. Dealer recommended not driving until repaired. 3) Dealer confirmed HCU failure with computer code analysis. 4) HCU and effected parts not inspected by anyone other than Dealer. 4) numerous red ABS and brake warning lights upon backing out of garage to street. I shut the engine off and restart in the hope of correction, to no avail. Problem re-occurred. Vehicle could be stopped but with difficulty -- slow to stop and hard to stop. Dealer replaced HCU assembly and ABS module and added PM1C brake fluid (DOT3), This HCU failure apparently has been a problem in Ford Fusion and other Ford vehicles (see Safety Recall 19S54 -Anti-Lock Brake System Hydraulic Control Unit Valve Function -- 2006-2010 Ford & Lincoln Mercury). It doesn't look like the problem has been resolved. Note that brake fluid used is DOT 3 and not the NTSB recommended remedy DOT 4 brake fluid

NHTSA ODI 11421551

UPON APPLYING BRAKE PRESSURE, THE PEDAL MUST TRAVEL A SIGNIFICANT DISTANCE BEFORE ANY BRAKING IS FELT. MY CAR HAS HAD NEW BRAKES PUT ON, WHERE THE MECHANIC HAS SAID THERE ARE NUMEROUS COMPLAINTS FROM OWNERS WITH THE SAME CAR. BRAKING DISTANCE IS SIGNIFICANT AND I AM ABLE TO FEEL THE FLOOR WITH MY FOOT. THIS SHOULD NOT BE THE CASE. FORD DOES NOT SEEM TO HAVE A SOLUTION, SO THEY CONTINUALLY PUSH IT UNDER THE RUG. I HAVE VERIFIED THAT MY MASTER CYLINDER IS WORKING AS EXPECTED WITH NO AIR IN MY LINES. I DO A LOT OF FREEWAY DRIVING, BUT IN ORDER TO STOP ON TIME, I HAVE TO GET OFF THE FREEWAY DOING 10 MPH LESS TO ENSURE I CAN BRAKE IN TIME.

NHTSA ODI 11414133

THE BRAKES ARE "SPONGY". TOOK IT TO OUR MECHANIC WHO REPLACED THE MASTER CYLINDER TWICE AND THE BRAKES WERE STILL "SPONGY". HE LOOKED AT THE BRAKES AND THEY LOOKED GOOD. HE RECOMMENDED THAT THE ABS SENSOR BE REPLACED, BUT FORD WOULDN'T SELL IT TO HIM. SO, WE TOOK IT TO THE FORD DEALER AND THEY REPLACED THE BRAKES, CALIPERS, ETC. AND THE BRAKES REMAIN "SPONGY". THEY SAID THEY NEEDED TO REPLACE THE MASTER CYLINDER, BUT IT IS BRAND NEW.

NHTSA ODI 11408473

WHEN IN MOTION, THE VEHICLE'S BRAKE PEDAL HAS EXCESSIVE TRAVEL, ALMOST NEEDING TO BE PUSHED TO THE FLOORBOARD BEFORE ANY BRAKING OCCURS. THE UNCERTAINTY OVER THE CAR'S BRAKING ABILITY MAKES IT DANGEROUS TO DRIVE. NO ERROR CODES OR ABS LIGHTS PRESENT. LOCAL REPAIR SHOP REPLACED BRAKE PADS AND ROTORS AND FOUND NO AIR IN THE SYSTEM WHEN THEY BLED THE BRAKES. THEY SPECULATED IT IS POSSIBLY THE HYDRAULIC CONTROL UNIT FOR THE ABS. THERE HAS BEEN A RECALL ON EARLIER FUSION MODELS FOR THIS ISSUE, BUT NOT 2012 MODELS FOR SOME REASON.

NHTSA ODI 11394527

BRAKE PEDAL BECAME SOFT AND THE BRAKING DISTANCE WAS INCREASED AFTER ABS ACTIVATION ON SNOW/ICE. I TAPPED THE BRAKES TO CHECK HOW SLICK THE ROAD SURFACE WAS, THIS ACTIVATED THE ABS. I THEN TRAVELED 30 FEET AND APPLIED THE BRAKES TO MAKE A RIGHT HAND TURN, THE BRAKES WENT NEARLY TO THE FLOOR CAUSING ME TO TAKE THE TURN AT A HIGHER THAN SAFE SPEED.

NHTSA ODI 11390457

ALL THSYMPTOMS THAT OCCUR AS DESCRIBED IN YOUR CAMPAIGN INVOLVING FORD RECALL NO. 19S54 AND SPECIFICALLY EA18-002. THE BRAKE PEDAL HAS EXCESSIVE TRAVEL BEFORE ENGAGING THE BRAKES. THIS SIGNIFICANTLY INCREASES BRAKING TIME. I HAVE HAD SEVERAL NEAR MISSES, ALMOST RESULTING IN ACCIDENTS.

NHTSA ODI 11365753

THE REAR BRAKE CALIBERS HAVE SEIZED UP TWICE NOW. 1ST TIME WAS JUNE 2017, SERVICED BY FIRESTONE, AND JUST RECENTLY SEPT 12TH 2020. BOTH TIMES REQUIRED A FULL BRAKE REPAIR. FIRST HAPPENED AT 72,000 MILES AND NOW AT 142,000 MILES. BOTH CAUSE A LOSS OF BRAKING IN THE VEHICLE. IN JUNE OF 2017 THE VEHICLE WAS MOVING BETWEEN 30 TO 45 MPH WHEN IT SEIZED UP. WE DROVE IT TO NEAREST SHOP IN ILLINOIS SO WE CAN START OUR DRIVE BACK TO GEORGIA. SECOND TIME WAS NOT AS BAD AS I RECOGNIZED THE SYMPTOMS AND GOT IT IN FOR REPAIRS BEFORE FULL SEIZURE OF THE BRAKES. ONLINE REVIEW SHOWS MANY PROBLEMS WITH THE BRAKES ON THIS CAR MODEL.

NHTSA ODI 11354770

POWER STEERING LIGHT CAME ON. STEERING WHEEL WOULDN'T TURN EASILY.

NHTSA ODI 11352467

BRAKE PEDAL DROPS ALMOST TO FLOOR AT TIMES GREATLY INCREASING STOPPING DISTANCE WHEN APPROACHING A STOP OR WHEN I SLOW DOWN. THIS NECESSITATES THE NEED TO PUMP THE BRAKE PEDAL AND IN EXTREME CIRCUMSTANCES NEEDING TO SWERVE TO AVOID A COLLISION . THIS PROBLEM OCCURS WITH NO WARNING AT ALL. THIS SEEMS TO BE A KNOWN ISSUE WITH THE FUSION.

NHTSA ODI 11331712

CAR WAS IDLING IN LINE AT A DRIVE THRU FOR ABOUT 5 MINUTES. DRIVER RELEASED FLOOR BRAKE TO MOVE UP IN LINE. AFTER PULLING UP A FEW FEET, AND THEN TRYING TO SLOW THE CAR, THE BRAKE PEDAL TRAVELED ALL THE WAY TO THE FLOOR AND BRAKING DISTANCE WAS EXTENDED. DRIVER WAS AFRAID THE CAR WOULDN'T STOP. CAR HAS A NEW ELECTRONIC THROTTLE BODY AND HYDRAULIC ABS PUMP, BUT PROBLEM PERSISTS. DRIVER IS CONSIDERING GETTING A NEW CAR. *TR

NHTSA ODI 11331012