What 1,455 owners told NHTSA about the 2016 Ford Fusion Energi

The contact owns a 2016 Ford Fusion. The contact received notification of NHTSA Campaign Number: 25V695000 (Back Over Prevention); however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that while reversing, the rearview camera failed to properly display an image. The dealer was made aware of the failure but confirmed that parts were not yet available. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 140,000.

NHTSA ODI 11747950

Back up camera screen is going out intermittently causing a hazardous situation

NHTSA ODI 11746980

EVAP blocking valve failed and car immediately went into limp mode on the highway. By doing this it could cause a crash. EVAP blocking valve also should last the life of the vehicle.

NHTSA ODI 11696645

The contact owns a 2016 Ford Fusion. The contact stated that while stopped in traffic or at a red traffic light on several occasions, on the way to an independent mechanic, the vehicle stalled. The contact stated that the vehicle was able to restart on each occasion after several attempts. The check engine warning light was illuminated. The contact stated that upon taking the vehicle to the independent mechanic and turning the vehicle off, the vehicle failed to restart. The mechanic diagnosed that the unknown sensor parts needed to be replaced. The vehicle was repaired, but the failure reoccurred a few months later. The vehicle was taken to the same independent mechanic on three occasions, where a tune-up was completed, and unknown parts were replaced; however, the failure persisted. The vehicle was taken to a dealer, where it was diagnosed with coolant intrusion into the cylinder due to a crack in the engine block. The dealer determined that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 70,000.

NHTSA ODI 11678494

My coolants been leaking starting at around 110k miles and it seems like the 2016 ford fusions with 1.6L are know to have coolant intrusions due to a defect in engineering by Ford. This problem eventually leads to corroded head gaskets and can cause the engine to basically explode in the middle of nowhere which is a safety concern. The costs of repair is over 4k+ for a new engine or just to replace the head gasket for something Ford engineers should be liable for. Please look into this and you may even look at my car if you like.

NHTSA ODI 11677695

The coolant was leaking i to the engine and caused a crack in the block leading to the need to replace the engine

NHTSA ODI 11677419

Dear NHTSA, I am reporting a potential safety and design issue related to my 2016 Ford Fusion Titanium with the 2.0L EcoBoost engine. The vehicle is experiencing coolant loss with no visible external leak, which is a documented issue under Ford TSB 19-2208. This condition can lead to sudden engine failure or hydrolock due to coolant entering the combustion chamber. A compression test revealed all cylinders at 155 psi, indicating the block has not yet failed — but the symptoms are known warning signs of the defect Ford acknowledged in its Customer Satisfaction Program 19N05, which does not include my VIN despite identical failure risk. Ford has refused to provide goodwill support under case [XXX], despite this being a well-known failure that has prompted engine replacements in other affected 2.0L EcoBoost models. Please document this case as part of your ongoing safety tracking. I believe this design flaw represents a serious long-term reliability and safety concern. Vehicle: 2016 Ford Fusion Titanium Engine: 2.0L EcoBoost Mileage at Onset: 130,000 approx. VIN: [XXX] Sincerely, [XXX] [XXX] [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11677306

My car is hard crank when put fuel in it. It also puffed out blue smoke.My check engine light is on.

NHTSA ODI 11676865

The engine coolant over temperature light came on and i was forced to pull off the side of the interstate because the car had lost most of it’s power. It’s my understanding the 1.5 L eco boist engines have a failure where they allow coolant to leak into the cylinder. We had the car looked at, let it cool down and the code cleared and drove home. This happened again and luckily we were close to a family members home and were able to limp the car there with very little power. The car was checked by a mechanic and they could not find a problem. The code was cleared and it drove fine again. Today the car did the same thing after a 30 minute drive and luckily we were close to home and once again limped it back to the house. I will be calling Ford in the morning to have it looked at.

NHTSA ODI 11676059

My engine died from the design error with the engine block and coolant leaking. This needs to be remedied by Ford. It is not on the recall list, and it absolutely should be.

NHTSA ODI 11675513

I own a 2016 Ford Fusion and the brake pedal stop bumper disintegrated and fell onto my floorboard. As a result, my brake lights stayed on, draining my battery. When I tried to drive, my car would not accelerate over 20 mph, and I barely made it home safely. I where it's extreme humid and salty air are constant, the same conditions identified in Ford’s 22S02 recall. Ford has stated my vehicle is not included, but this is a clear safety hazard identical to the recall issue. I request that NHTSA investigate and include my vehicle in the 22S02 recall.

NHTSA ODI 11675595

Coolant intrusion 1.5l

NHTSA ODI 11675740

The contact owns a 2016 Ford Fusion. The contact stated that after her son started the vehicle, the steering wheel was difficult to turn in either direction. The cause of the failure was not yet determined. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The contact was informed that the VIN was not included in NHTSA Campaign Number: 18V167000 (STEERING). The contact stated that the vehicle had experienced the failure listed in the recall. The failure mileage was unknown.

NHTSA ODI 11675265

The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the rear driver’s side door opened independently. After a visual inspection, the contact observed that the door had failed to latch securely. The door ajar warning light was illuminated. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 23V775000 (Latches/Locks/Linkages), but the VIN was not included. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 130,000.

NHTSA ODI 11675176

The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the vehicle briefly shook violently, prompting the contact to discontinue driving the vehicle. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who determined that there was coolant intrusion into various cylinders resulting in damages to the engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. After investigating the failure, the contact related the failure to Customer Satisfaction Program: 21N12. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 99,900.

NHTSA ODI 11673635

The contact owns a 2016 Ford Fusion. The contact stated while driving 60 MPH, the vehicle inadvertently lost motive power. The contact was able to pull over to the shoulder of the roadway, where the vehicle was able to restart. After restarting the vehicle, the vehicle returned to normal functionality, but the failure became a regular occurrence. No warning lights were illuminated. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 150,000.

NHTSA ODI 11673666

Coolant intrusion into cylinder 1, low coolant and Engine DTC P0301. Multiple TSB's by Ford recommend engine replacement as a remedy for the Cylinder head - open deck cooling problem. Customer Satisfaction Program 21N12 addresses this problem in similar cars/engines. Has this been expanded to cover this vehicle with the same 2.0L engine? From Ford TSB 19-2346 "Issue: Some 2015-2018 Edge and 2017-2019 Fusion/MKZ/Escape/MKC vehicles equipped with a 2.0L EcoBoost engine may exhibit a low coolant level, white exhaust smoke and/or a runs rough condition with or without an illuminated malfunction indicator lamp (MIL). Diagnostic trouble codes (DTCs) may include P0300, P0301-P0304, P0316, P0217, P1285 and/or P1299 stored in powertrain control module (PCM). This may be due to coolant intrusion into the cylinder. To correct the condition, follow the Service Procedure steps to replace the long block engine assembly."

NHTSA ODI 11672866

My 2016 Ford Fusion SE 2.0L Turbo has been emitting some white smoke, then the other day it would not start right away. When started it ran rough for a few minutes on idle and when driving it does not have much power anymore and it would hesitate a lot if trying to accelerate. SO getting on the interstate that morning I nearly got rear ended by a semi-truck because I could not accelerate up to speed. The check engine light came on shortly and I took it to a mechanic who did tests to diagnose. The diagnostic showed misfiring in cylinder 2 most likely due to coolant intrusion. After doing some research it was evident that many owners have had this happen and had to replace their entire engine for 6000+ dollars. My car only has 114,000 miles on it and it should function properly. I have seen cars with 250,000+ miles easily.

NHTSA ODI 11670981

engine light turned and, scanned it and code is P0301 Cylinder 1 Misfire detected. Coolant is leaking into the engine. I have looked online and multiple people have had this issue, majority of them taking their vehicles to Ford dealers and being told they need an engine replacement. I have taken my vehicle to a mechanic shop and was told the same thing. my safety was at risk because this issue caused my engine to overheat and the engine would not turn on for a while after. with coolant being mixed in with the oil, it damages the engine and can cause the car to stop being functional while you are still operating it. I am also including a link to a website that has proof that Ford delearships have seen this issue before, are aware of it but do nothing to fix it [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11670602

Electric Power Steering Motor Attaching Bolts Corrode (NHTSA 19V-632, OEM 19S26): Corrosion of bolts in the electric power steering system can lead to loss of power steering assist in 2016 Ford Fusion and Lincoln MKZ vehicles in certain states. Dealers will replace bolts and apply a sealant, or install a new steering gear.

NHTSA ODI 11670412

Driver side seat belt suddenly stopped working. Initially it was stuck and would not deploy. Eventually it released and was able to be drawn and buckled, but does not restrain passenger when tested manually; driver was not restrained when the car was braked quickly. rom 35 mph to a full stop. There is a December 5, 2016 NHSTA recall on front seat belts May not restrain Occupants (NHSTA Campaign number 16V875000) and and a Ford Recall number 16S42. Car was purchased from a Ford dealer in 2018-2019 as a used vehicle. Current dealer indicates it may cost from $400-1200 to replace the seat belt.

NHTSA ODI 11669911

purchased a used vehicle. At the time of purchase, there were no visible issues with the car. However, approximately 20 days later, a significant jerking and knocking problem related to the transmission appeared. Due to this issue, I stopped using the vehicle for a while. After consulting with a mechanic, I was informed that the transmission needs to be replaced. As of now, the car is struggling significantly to move. When I turn the ignition, the engine starts, but the vehicle does not move. If I turn the ignition off and restart it, it may move slightly after shaking the vehicle, but then it quickly stops and displays an error again. In this condition, the vehicle is not drivable. Unfortunately, the person I bought the car from refused to accept any responsibility or take the car back, despite my clear communication about the issue. Additionally, the following issues have also started to occur: The steering wheel becomes stiff suddenly. This resolves temporarily after turning the ignition off and on again. The brake pedal sometimes vibrates as if it’s losing pressure. I can clearly feel this under my foot while braking. Sensor malfunctions have also started to appear. The current condition of the vehicle poses serious safety and functionality concerns. Unfortunately, I am not financially able to cover any additional repair costs. Therefore, I would like to know if there is anything legally or technically that can be done regarding this matter. Otherwise, I will be forced to sell this vehicle as scrap. Thank you in advance for your support and assistance. Sincerely,

NHTSA ODI 11669237

The contact owns a 2016 Ford Fusion. The contact stated that while driving at various speeds, an abnormal knocking sound was coming from the vehicle. The contact's husband changed the spark plugs; however, the failure persisted. The failure persisted, and the check engine warning light illuminated. The vehicle was taken to an independent mechanic where it was diagnosed with coolant intrusion into the cylinder, resulting in engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. Several dealers were notified of the failure; however, each dealer informed the contact that there were no recalls related to the VIN. The manufacturer was made aware of the failure and provided a case number. The contact was referred to the NHTSA Hotline for further assistance. The failure mileage was approximately 117,000.

NHTSA ODI 11668195

I purchased a 2016 Ford Fusion S new from the dealership in 2016. Earlier this year, multiple indicator lights turned on including "Service AdvanceTrac", ABS light, steering and hill assist lights. As time progressed, the Power Steering has become more of an issue to a point now that it is difficult to make tight turns going at low speed. I never received a recall notice, but when I did a search of the 2016 Ford Fusion S vehicle, there is an outstanding recall on similar models in 19V632000. The list of states include the state of Missouri which is where the vehicle was purchased from. At the time the recall notice was sent out (August 28, 2019), the vehicle would have been registered in Kansas. A search by the VIN number does not show a recall notice for it. Presently, the vehicle is registered in Iowa. I hope to get review of my VIN number to see if this recall should have included my vehicle as there are similar models distributed in similar states, with exact issues pertaining to my vehicle which was not included in the initial recall. I have service scheduled for this vehicle at an authorized Ford dealership on July 17th, 2025 which was the earliest I could get the car in. I'm concerned as this is a substantial issue that puts the vehicle at risk for a serious malfunction should the power steering fail completely while being operated. This is a relatively low mileage vehicle for the year which likely why the issue hasn't arose until this point. I appreciate your time and consideration on this matter.

NHTSA ODI 11667531

Coolant intrusion causing engine failure per diagnostic TSB 22-2134 applies.

NHTSA ODI 11667533