What 175 owners told NHTSA about the 2020 Ford Fusion

I am reporting a life-threatening incident involving my 2020 Ford Fusion PHEV. On December 5, 2025, while my wife was driving on a public street, the vehicle suffered a sudden, complete engine failure followed by smoke and fire originating from the high-voltage battery pack in the trunk. There were no prior warning signs or dashboard alerts before the incident. This vehicle was sold via IAAI auction in September 2023 without disclosing the active, critical safety recall (NHTSA 23V440 / Ford 23S33) issued in June 2023. This non-disclosure placed my family in extreme danger. When the fire started, my wife was in a state of panic. I arrived at the scene before emergency services. Being a technician, I performed a high-risk manual extraction of the burning battery pack to prevent the entire vehicle and the surrounding residential area from a potential explosion. I risked electrocution and toxic chemical exposure to save lives. The damaged battery pack is currently preserved and available for professional inspection upon request. As a result of the fire and exposure to extinguisher chemicals, I suffered respiratory distress and asthma-like symptoms for several days. I have contacted Ford Motor Company through official channels and documented all interactions. Ford representatives stated that they 'only assist customers in the United States' and local representatives in [XXX] have officially refused to provide the remedy, stating they are not authorized or equipped for this specific recall. I am now left with a charred, unusable vehicle. I demand a full investigation into the failure of the recall remedy process and manufacturer liability for these life-threatening damages. ( Form fields about my location are place holders. Contact me in [XXX] (Country) at [XXX] / [XXX] ]. I hope you do don't ignore our lives due to geography. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11725471

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

Water is leaking into the trunk of our vehicle through the tail light assembly and soaking all the electrical wiring in the base of the trunk. The wheel well is becoming flooded with water. All the wiring going in and out of the trunk is soaking wet. If you Google this issue. Other Ford Fusion owners with older model vehicles and the same tail light assembly are having the exact same issue where water is coming into the trunk from the tail light assembly. This is clearly a design flaw and with water coming inside and covering the electrical system I want to believe this is major safety concern.

NHTSA ODI 11494404

I purchased this vehicle on Mar 4 2020 at Al Spitzer Ford in Cuyahoga Falls, OH with only 11,800 miles.I am getting the run around with their service department. The vehicle does not have a hoodliner insulator installed. It's needed to control temperature, protect paint and reduce engine fires. This is Ford's way along with the dealership to cut costs. The vehicle is covered under warranty and is metallic black which will attract the heat

NHTSA ODI 11463957

TL* THE CONTACT OWNS A 2020 FORD FUSION. THE CONTACT STATED THAT THE BACKUP CAMERA REMAINED ON WHILE DRIVING AT AN UNKNOWN SPEED. THE VEHICLE WAS TAKEN TO THE ROYAL OAK FORD DEALER, LOCATED AT: 27550 WOODWARD AVE, ROYAL OAK, MI 48067, WHERE THE SENSOR WAS REPLACED. THE CONTACT STATED THAT WHILE DRIVING HOME, THE VEHICLE HIT A POT HOLE, THE FRONT PASSENGER'S TIRE WENT FLAT. THERE WAS NOT SPARE TIRE. THE CONTACT'S HUSBAND PURCHASED A NEW TIRE, JACKED THE VEHICLE UP TO REPLACE THE TIRE. WHILE ON THE JACK, THE VEHICLE WENT IN REVERSE, ROLLED BACK AND FELL OFF THE JACK. THE VEHICLE WAS TAKEN TO THE SAME DEALER WHO STATED THAT THE VEHICLE WAS NOT EQUIPPED WITH A SPARE TIRE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURES AND REFERRED THE CONTACT TO THE DEALER. THE CONTACT WAS TOLD TO TAKE THE VEHICLE TO A BODY SHOP TO REPLACE AN MUD GUARD THAT DETACHED. THE PART WAS NOT REPLACED. THE FAILURE MILEAGE WAS 4,051.

NHTSA ODI 11328319