What 175 owners told NHTSA about the 2020 Ford Fusion

Rear Package Tray Trim disintegrating due to sun exposure, the carpeted fiber trim behind the rear seats underneath the rear windshield. The part is still installed in my vehicle, but it available to be inspected I am constantly finding ultra fine black fibers throughout my car's trim/dashboard/steering wheel/infotainment/vents, on my clothes and in my hair especially after driving with my windows down from the trim piece fibers disintegrating. Because the fibers are blown throughout the car this is a health hazard as you are breathing in fiber strands, similar to why asbestos has been banned. A Ford dealership has inspected the part to see if there are any Ford recalls and to quote replacement of the part. First started noticing the black fibers about a year ago but that was only when the part was touched as it would cover your hand/arm in the fibers. It has progressively gotten worse to where air will now cause further disintegration of trim and blow the fibers throughout the car.

NHTSA ODI 11601303

The engine is “eating” the coolant causing the vehicle to overheat and break down.

NHTSA ODI 11598390

The contact owns a 2020 Ford Fusion. The contact stated while operating the vehicle, there was a loud knocking sound coming from the engine compartment and the battery had failed. The vehicle was taken to the local dealer who diagnosed that the transmission flex plate had failed. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 102,864.

NHTSA ODI 11586070

The contact owns a 2020 Ford Fusion. The contact stated that while starting the vehicle, there was a rattling noise coming from the front end near the driver’s side close to the transmission. The vehicle would start moments after the failure had occurred. The rattling was more pronounced while the A/C system was running. The contact stated that while depressing the accelerator pedal, the rattling sound was noticeable. Additionally, while driving at various speeds, the transmission felt as though it was slipping while changing gear. The contact stated that while inspecting the engine, underneath the hood was hotter than normal. The check engine warning light was illuminated. The vehicle had been taken to the dealer where it was diagnosed that the transmission flex plate had failed. The failure was linked to NHTSA Campaign Number: 10218899 (Power Train). The vehicle had not been repaired. The manufacturer was made aware of the failure, and it was confirmed that the VIN was not under recall. The contact was referred to the NHTSA Hotline to file a complaint. The failure mileage was 117,000.

NHTSA ODI 11586075

Cracked flexplate

NHTSA ODI 11585753

The entire media display gets stuck off or will freeze up, when I place the vehicle in reverse the rear camera comes on but parking assist, the rear sensors and cross traffic sensors won't work. Once I place the car in drive the display will either stay all blue or shut completely off. I cannot adjust the climate control, use GPS, or use the media. I have to shut the car off and then after about 10 minutes there is a bunch of clicking noise under the dash and after it stops clicking I can restart the car, the display will sometimes begin to work and if it dossent then I have to shut off the car again and go through the motions again. It has started to be more and more frequently, at first it was maybe once a week and now it is happening at every start.

NHTSA ODI 11585519

Rattling and lost of power

NHTSA ODI 11584954

Intrusion into cylinder 2.

NHTSA ODI 11584802

The contact owns a 2020 Ford Fusion. The contact stated while starting the vehicle, the vehicle made an abnormal rattling sound. The contact stated that the failure had been recurring. The vehicle was taken to an independent mechanic, where it was diagnosed that there was a rattling sound coming from the transmission bell housing area, and the flex plate was cracked. The vehicle was not repaired. The manufacturer was notified of the failure and informed the contact that the failure was related to Ford Campaign Number: 22N12. The manufacturer assisted the contact in scheduling an appointment with the dealer for diagnostic testing. The manufacturer also referred the contact to the NHTSA Hotline for assistance. The vehicle was not repaired. The failure mileage was approximately 95,755.

NHTSA ODI 11575600

The contact owns a 2020 Ford Fusion. The contact stated that while driving at an undisclosed speed, the vehicle failed to accelerate as intended. The contact stated that the vehicle was shaking, and the vehicle lost motive power. In addition, the contact heard an abnormal rattling sound, and the transmission was slipping. The vehicle was taken to the dealer and the contact was advised to flush the transmission fluid. The contact stated that after flushing the transmission fluid, the failure ceased but later returned. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The contact stated that after researching the failure, the contact discovered TSB: 22N12. The contact informed the dealer of TSB: 22N12 and the contact was informed that the repair was not eligible to be covered under TSB: 22N12. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The manufacturer was made aware of the failure but did not assist. The failure mileage was approximately 45,000.

NHTSA ODI 11574552

The vehicle has 87390 miles and the shifter grommet broke just like recall 19s16. 2020 fustion with a 1.5l engine.

NHTSA ODI 11572079

The flexplate was cracking and rusted which caused starting and acceleration problems. Yes, it's available per request. It's currently with the transmission shop that fixed my vehicle. There was a rattling noise found in neutral and park by the transmission shop I took it to. My safety was put at risk because my ability to control my car's power was affected. I was at risk of a loss of power to the wheels which could have caused a major accident, especially because most of my driving happens on the interstate at speeds of 65-7 mph. The issue has been confirmed by an independent service center. Yes, they inspected by the techs at the transmission shop. There were no warning lamps or messages before the failure. The symptoms were a rattling noise and reduced power. This issue is well documented online and is known to happen in the 60-90k mile range which I can confirm based on my personal experience and others. References: [XXX] [XXX] [XXX] [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11570764

The contact owns a 2020 Ford Fusion. The contact stated that on several occasions while driving at various speeds, the gear was shifted, and the vehicle reverted to park. The vehicle was restarted approximately five to ten times on all but one occasion, and the vehicle failed to start. The vehicle was towed to a dealer where it was diagnosed that the shifter cable bushing needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was approximately 93,200.

NHTSA ODI 11570486

Flexplate cracked. Causing vehicle to make a loud noise when idle or driving in reverse. Cracked discovered by mechanic and Ford service department. No warning lights or other issues prior to crack.

NHTSA ODI 11566139

The contact owns a 2020 Ford Fusion. The contact stated while driving approximately 60 MPH, the vehicle changed lanes independently. The vehicle was steered to the side of the road. The vehicle was taken to a dealer where it was diagnosed that the steering control module was informing the steering wheel to turn to the left while the vehicle was to the right and vice-versa. The contact was informed that the steering control module needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 66,620.

NHTSA ODI 11563755

The flex plate is bad and ford won’t fix it. It needs recalled before it kills someone. Flex plate is the plate that puts power from engine to transmission

NHTSA ODI 11558385

On hot days the Forward Collision will show as unavailable, but there is no notification saying when it will be available again. This is dangerous in that a safety feature on the vehicle is unavailable when it is hot outside and has been sitting in the sun. Outer door panel skins are becoming unattached from the door frame, which could cause an issue if the skin fails elsewhere that it would be totally unattached to the door frame and fall off when driving. The rear package tray trim (carpeted trim piece behind the rear seats covering the speakers) disintegrates when it is touched due to it being exposed to the sun. Discovered when attempting to clean inside of my rear window. This has caused black particulate to be scattered throughout the vehicles interior. They are small enough that you could be breathing them in as the debris has been found all over the dashboard, seats, infotainment console, and trim all around the car. This is a health hazard due to breathing in fabric/carpet particulate that can irritate the lungs. Link to forum of other people having the same issue: https://www.fordfusionforum.com/index.php?app=forums&module=forums&controller=topic&id=20981#comments

NHTSA ODI 11555899

The contact owns a 2020 Ford Fusion. The contact stated while driving at an undisclosed speed, the contact heard an abnormal knocking sound coming from the engine compartment. The vehicle was taken to the dealer and diagnosed with a failed flex plate and torque converter. The contact was informed that the flex plate and the torque converter needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 63,000.

NHTSA ODI 11555084

Failure of the Flywheel. It’s broken in pieces according to the dealership at greenway Ford. Did some searching on line and other people have report the same issues. The problem is they installed crappy plates that crack between 60k-90k miles. As others have reported the Luckily for them It was at an intersection and could pull over to the side of the road but imagine if this happens to you while on the freeway!

NHTSA ODI 11554830

The contact owns a 2020 Ford Fusion. The contact stated while driving approximately 55 MPH, the contact became aware that the vehicle was losing motive power. The contact stated that the RPM was fluctuating. The contact stated that the check engine warning light was illuminated. The contact stated that the vehicle stalled but was able to be restarted. The contact stated that the failure had occurred three other times. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the tube assembly fuel vapor separator (9D289) needed to be replaced. The vehicle had not been repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 102,495.

NHTSA ODI 11554045

Car has the same 6f35 transmission issues as previous years and nothing is being done about it my car has 63k on it with a dead transmission because of the flexplate issue from previous years

NHTSA ODI 11554094

As I was crossing an intersection, a vehicle ran through a red light and hit the front of my vehicle. There was significant damage to the whole front end and my vehicle was shifted to the left due to the impact. My air bags did not deploy. I injured my head and neck by striking the sun visor which cause a laceration and a cervical strain. My vehicle has been maintained well and there was no indication of air bag malfunction prior to the crash. Insurance adjuster has not inspected the vehicle yet.

NHTSA ODI 11549741

APIM is faulty per the ford dealer ship. (Rusty Eck Ford) They state that it is a known issue but there has not been a recall. This affects the SYNC, navigation, instrument panel, connectivity to ford connect app, etc. In order for some things to be used temporarily, it has to be hard reset on the console. Nothing leading up to the issue.

NHTSA ODI 11549347

The contact owns a 2022 Ford Fusion. The contact stated that on several occasions while in reverse, the proximity warning alert did not sound as designed. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was unknown.

NHTSA ODI 11548383

The contact owns a 2020 Ford Fusion. The contact stated while driving 30-35 MPH, the vehicle made an abnormal rattling sound. There was no warning light illuminated. The contact was able to continue driving. The contact stated that the vehicle failed to start the following day and was parked. The vehicle was towed to the dealer, where it was diagnosed that the flywheel had failed and needed to be replaced. The dealer informed the contact that the vehicle could not be repaired under Ford Campaign Number: 22N12 because the campaign had exceeded the required mileage. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 120,251.

NHTSA ODI 11547780