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

There is a very common problem with the fusions on coolant intruding into the engine. This problem needs to get fixed as it is a Ford problem.

NHTSA ODI 11617865

The contact owns a 2016 Ford Fusion. The contact stated that on two occasions while the vehicle was parked, the check engine, ABS, parking brake, traction on/off, and power train warning lights illuminated. Additionally, the steering wheel became firm. The vehicle was taken to an independent mechanic where it was diagnosed that the electronic power steering module needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 165,000.

NHTSA ODI 11617489

I am writing to file a formal complaint regarding my 2016 Ford Fusion Hybrid, which I purchased in late June 2024. Despite the ongoing issues with my vehicle, it does not appear on the NHTSA recall list, even though many other Ford owners are experiencing similar problems. Recently, I encountered severe symptoms, including a persistent coolant leak and a puff of white smoke from the tailpipe. Initially, the dealership diagnosed the issue as a simple battery problem related to a cylinder 4 misfire. Following their advice, I spent nearly $500 on a new battery and diagnostic fees. Unfortunately, after driving the car, the engine light reappeared, indicating that the initial diagnosis was insufficient. Upon further inspection, the technician found a puddle of coolant on top of piston 4, which suggests a significant internal problem. This situation mirrors complaints from other Ford owners regarding their EcoBoost engines, even though my hybrid engine is not classified as EcoBoost. I am concerned about the lack of action regarding these issues, especially since they pose serious safety risks. Additionally, I have been informed by Ford that an engine tear-down is necessary to diagnose the full extent of the problem. If deemed not covered under my warranty, I will be responsible for $1,710 for the tear-down alone, with an estimated cost of around $11,000 for a new engine. As a college student with limited income from a part-time job, I cannot afford these expenses. I urge the NHTSA to investigate this matter and consider the broader implications for all affected Ford vehicles. I look forward to your prompt response. These unresolved issues not only threaten my safety but also potentially endanger others on the road. My repeated attempts to seek support from Ford have been met with inadequate responses, leaving me frustrated and without a clear path forward. I urge the NHTSA to investigate my case and consider a broader review of similar Ford vehicles

NHTSA ODI 11616835

Engine replaced under recall in 2021 due to coolant intrusion issue. Replaced with similar faulty engine. This is a possible fire hazard. Ford will do NOTHING. It's unacceptable that an 8 year-old car needs a third engine. Worst service EVER. Putting my daughter's life at risk

NHTSA ODI 11616560

Engine replaced under recall in 2021 due to coolant intrusion issue. Replaced with similar faulty engine. This is a possible fire hazard. Ford will do NOTHING. Its unacceptable that an 8 year- old car needs a third engine. Worst service EVER. Putting my daughters life at risk.

NHTSA ODI 11616618

Coolant intrusion..

NHTSA ODI 11616096

The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the vehicle lost motive power with the check engine warning light illuminated. The vehicle was able to restart however, the failure recurred. The vehicle was taken to an independent mechanic where it was diagnosed that the electronic throttle body had failed, and the engine needed to be replaced. The vehicle was not repaired. The vehicle was towed to the dealer where it was diagnosed that the battery had failed and needed to be replaced. The vehicle was repaired, however the failure recurred. The vehicle was towed back to the dealer where it was diagnosed that the electronic throttle body had failed, and the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance. The failure mileage was approximately 106,000.

NHTSA ODI 11616006

Engine started to misfire at 70k miles, took to a shop and had to get an engine replaced. As a college student, a $7,000 bill put me behind in school. This is a common issue on the 1.5 and 2.0 ecoboost engine and Ford knows it's a problem, hints the engine redesign in 2019.

NHTSA ODI 11615805

Ford has multiple bulletins for 2016 Fusion - EcoBoost Engine. Ford dealer did not address any of the issues upon numerous service visits. Despite engine light being on. Suffered catastrophic failure of engine resulting in loss of power while driving.

NHTSA ODI 11613393

The car locked in Neutral but the gear shift is locked in Park. The bushel broke, which was a recall on my make and model but does not show when I search for recalls on my vehicle.

NHTSA ODI 11613429

According to the Ford dealership, I am missing a piece of a gasket which is causing coolant issues. I was told that there was a flaw with the engine design on my vehicle wherein instead of repairing/replacing the gasket, an entire engine is needed- making my vehicle a total loss now. When questioned if this was the result of anything I did or could have prevented, I was informed that this was not anything I caused or could be avoided as Ford created a faulty engine design.

NHTSA ODI 11612322

I have a coolant intrusion on cylinder number three. It is a Ford defect. It should be Under recall

NHTSA ODI 11610784

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed, the coolant warning light illuminated, and the engine temperature became elevated. The vehicle was taken to an independent mechanic; however, the contact stated that after repairing the vehicle, the failure persisted. The vehicle was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The contact was advised to take the vehicle to the dealer for assistance. The manufacturer was made aware of the failure but provided no assistance. The contact was informed that the repair was not covered under Technical Service Bulletin: 16-0150. The contact was referred to the NHTSA Hotline to report the failure. The failure mileage was approximately 68,000.

NHTSA ODI 11609796

Had a coolant leak which further damaged my whole engine. i need a new one now after only having my car for 2 years.

NHTSA ODI 11609544

Engine failure, water intrusion, they issued a recall for 2013 - 2018 1.5l and 2.0l, but not my vehicle. It's doing what they recalled. I have a appointment to get checked out and have recalls completed. There is a lot of people with this issue and no recall for their vehicle.

NHTSA ODI 11607693

Internal coolant leak in cylinders.

NHTSA ODI 11607551

I was driving on the interstate when smoke started from the rear of my car and the engine started sputtering. the vehicle started to slow down in heavy traffic. I was caught in the traffic and could not get off the road, the temperature gauge suddenly moved to the red on the gauge and I could not see the back of my vehicle making it dangerous to pull off the interstate. II had my grandsons with me making this worse. I had the car towed to my fathers garage where he then did a compression test on all four cylinders and found #4 cylinder to be very low reading compared to the other 3 cylinders as well as a pressure test of the radiator which showed a large leak off. I had no warning or messages when this happened

NHTSA ODI 11606650

The contact's girlfriend owns a 2016 Ford Fusion. The contact stated that while his girlfriend was reversing, the front wheels seized, and the vehicle was shaking. The vehicle then lost motive power. The check engine warning light was illuminated. The vehicle was towed to an independent mechanic, who determined that there was coolant intrusion into the engine and that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 147,000.

NHTSA ODI 11606188

2016 Fusion Titanium has the 2.0L Ecoboost engine with the coolant intrusion issue. This is a known issue with both Ford and the NHTSA, but after being diagnosed by a ford dealership, Ford Motor Co. will not provide any assist because it is not listed on any TSB or does not have an active recall. The models that are listed are the Edge, Focus, MKZ, and the Fusion, but Fusion models start at 2017 on the TSB. This is not accurate information because the exact same engine that is used in the Focus/Edge models and year range is used in the 2016 Fusion.

NHTSA ODI 11605624

Misfire #3 cylinder, coolant loss with no external signs of coolant leak. White smoke out exhaust when driving. Overheating

NHTSA ODI 11605268

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed, the engine seized. The contact stated that the failure had occurred two times since July of 2023. The vehicle was taken to an independent mechanic where it was diagnosed with coolant intrusion and engine failure. The contact was informed that the engine needed to be replaced. The manufacturer was made aware of the failure. The contact was made aware of Customer Satisfaction Program: 21N12 (Short Block Replacement After Coolant Intrusion); however, the vehicle was not included. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 120,000.

NHTSA ODI 11604350

There is a " design flaw" with the vehicle where coolant leaks into the cylinder heads and you have to replace the whole engine. I have read about it in the Internet when my check engine light came on and gave me cylinder 2 misfire code.I started the car and the check engine light was off. I tried to get to work that morning and the car shut off on the middle of Interstate 81 with no warning. It was a very dangerous situation where I got stuck until it came to a complete stop and turn it back on. White smoke poured out of the tail pipe, I went home. I spoke with a Ford representative who said it is a design flaw in this engine and the whole thing needs to be replaced, with engines starting at $5,000 plus 4 days labor. He advised that the problem could happen again with the replacement. I know there is nothing you guys can do but my car died in 2 days.i have a $20,000 to pay off and only had this car a year and I am going to have to give it back and keep paying for it, for 5* years. I feel so upset and cannot believe Ford is doing this to people and getting away with it. This ruined my life and I will probably lose my job now cause I have no means of transportation. This needs to be recalled! It's not right

NHTSA ODI 11603600

Coolant leaked into a cylinder due to a failed head gasket at 61,000 miles. Ford replaced head gasket, but the issue is due to poorly manufactured engine, and I had the same issue starting again at 99,000 miles. Ford refuses to fix engine since it is out of warranty, but the issue is due to poor manufacturing, not customer negligence.

NHTSA ODI 11603658

Component failure: Engine -- Catastrophic engine failure due to coolant leakage onto the engine block. EcoBoost engine. Dealership confirmation that car engine will need full replacement - car essentially scrap metal without new engine. At the time of this failure car had approximately 40,000 miles odometer read total on it and maintenance was up to date. Personal safety - I was driving the car on a Freeway with other vehicles at approximately 65 mph and the entire car began to shudder and I lost the ability to accelerate. The road was on an uphill trajectory and I was in the middle lane - I had to navigate my vehicle to the right hand lane and off the freeway at the next exit - I and others were at high risk of a collision due to the severity and sudden failure of the engine while on a busy road. Dealer confirmation: Dealership had specific codes on the diagnostics decribing this issue. Repair offered was replacement of the long block with a Ford engine that had been modified to fix the coolant leakage problem. Essentially Ford was offering a new TYPE of engine instead of a fix with the same model the car originally had. Dealership was aware of this engine coolant issue with Ecoboost, they revealed Ford was aware of the issue but never issued a recall. We were given the customer complaint line and were told FORD has been offering SOME people new engines at no cost. We were rejected by Ford customer line and told to file a complaint here. Essentially described by dealership repair as need to replace the long block (entire engine) to fix the problem or replace the short block only to expect it to happen again. The cost to replace the long block was quoted at 9500.00. Inspection and repair worksheets available from owner. Warning signs: NONE. Check engine light came on approximately 30 seconds AFTER symptoms on freeway began.

NHTSA ODI 11602850

My car has about 120k miles on it. The issue is that the coolant leakes into the cylinders. Tried replacing cylinders but problem came back. Dealership says the engine needs repair. The safety issue I had was I was driving on the hwy at about 60. The car suddenly went from 60 to 30. If a car had been behind me I would have been hurt. The manufacturer ford will not pay. I have seen many of this exact same issues on your website. This IS a safety issue. What can you do?

NHTSA ODI 11601032