2015 Ford Fusion Energi

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

In December 2019, the Office of Defects Investigation (ODI) opened this investigation based on 235 Vehicle Owner Questionnaires (VOQs) alleging doors failed to latch when closed, and/or inadvertently opened while driving, on model year (MY) 2012-2014 Ford Fiesta, and 2013-2014 Fusion and Lincoln MKZ. Some VOQs reported the failure occurred after the latch had been remedied under a prior recall which involved fracture of the latch pawl spring tab due to thermally induced cyclic fatigue. Other VOQs alleged a similar failure in vehicles not previously recalled. A latch with a fractured pawl spring tab typically results in a ?door will not close? condition, however in certain somewhat rare circumstances, may result in the door coming open while driving. In response to ODI?s investigation, Ford has announced three field actions, as discussed below.On March 23, 2020, Ford submitted Safety Recall 20V-177 (Ford 20S15), a regional recall campaign to address door latch failures in vehicles not previously recalled under Safety Recalls 15V-246, 16V-643 and 17V-210. The recall affects vehicles currently or ever registered in certain high ambient temperature states (see 20V-177 for affected states). As a remedy, Ford will replace all four door latches free of charge.On August 24, 2020, Ford issued a non-safety regional field action (Ford 20R01) to address door latch failures on the same model/MY vehicles not covered under 20V-177 (i.e., not currently/ever registered in affected states). According to Ford, spring tab failure rates for vehicles covered by this action are about half that of the 20V-177 vehicles. Under this action, dealers will replace all door latches, free of charge, if either; a) the vehicle exhibits a related latch concern, or b) if the vehicle owner expresses a concern about the latches in their vehicles. Details can be found under NHTSA TSB No. 10190990, a copy of which is available in this investigative file available at NHTSA.gov.On June 8, 2020, Ford submitted Safety Recall 20V-331 (Ford 20S30) addressing vehicles previously remedied under NHTSA Recalls 15V-246, 16V-643 and 17V-210, where the repair may not have been properly completed, specifically not all of the door latches were replaced, or replaced correctly. This recall involves an inspection of the latches, with the option for a consumer self-inspection; owners could view the date codes on their latches (and confirm child safety locks are present on the rear doors) and then submit the information to Ford?s mobile app or website. A dealership inspection option was also available. Any vehicle found to have unreplaced defective latches requires the replacement of all door latches as directed by Ford.Regarding the 4,494 reports cited above, 1,485 involve scope-related failures (with 13% alleging door opening), and the remaining 3,009 reports involving remedy concerns (with 18% alleging door opening - note ODI was unable to verify the allegations of door opening). The three ODI injuries were all relatively minor. Ford?s reported injury incidences include one (unconfirmed) report of an ejection, three minor injuries with the others involving undisclosed injuries. Ford?s crashes involved two (unconfirmed) crashes alleging the incident door contacted another vehicle and three involving doors striking other property.The recalled vehicles include MY 2011-2015 Ford Fiesta, 2013-2016 Ford Fusion and Lincoln MKZ, 2015 Ford Mustang and Lincoln MKC, 2013-2015 Ford Escape and Ford C-MAX, 2012-2015 Ford Focus and 2014-2016 Ford Transit Connect.Ford's actions address ODI's concerns at this time. ODI will take further action if warranted by new information. The reference (OD

The contact owns a 2015 Ford Fusion Energi. The contact stated while driving at various speeds, the steering wheel became difficult to turn to the left or the right. The contact stated that the ABS and traction control warning lights were illuminated. The vehicle was towed to a local dealer where it was diagnosed and determined that the electrical rack and pinion needed to be replaced and recalibrated. In addition, the contact linked the failure to NHTSA Campaign Number: 15V340000 (Steering); however, the VIN was not included. The vehicle was not repaired due to costs. The manufacturer was made aware of the failure. The failure mileage was approximately 100,008.

NHTSA ID

11660403

Incident

Apr 15, 2025

Mileage

100,008 mi

The contact owns a 2015 Ford Fusion. The contact stated while driving approximately 55 MPH, the vehicle lost motive power. The contact stated that upon inspection, an oil leak was found. The vehicle was towed to an independent mechanic; however, the vehicle was not diagnosed or repaired. The vehicle was towed to a local dealer where it was diagnosed and determined that the engine needed to be replaced due to several holes and cracks being found on the engine block. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 150,000.

NHTSA ID

11617448

Incident

Jul 7, 2024

Mileage

150,000 mi

The contact owns a 2015 Ford Fusion Energi. The contact stated while driving approximately 45-60 MPH, the vehicle started making an abnormally loud humming sound while releasing the accelerator pedal. The contact stated that upon depressing the accelerator pedal, the vehicle hesitated and jerked backward several times. The contact was able to continue driving; however, the failure reoccurred increasingly while driving the following day. The warning message "Engine coolant temperature - Pull Over As Soon As Possible" was displayed. The contact veered to the side of the road. The vehicle was towed to the local dealer where the failure was diagnosed as a transmission failure. The dealer informed the contact that the repair would be covered by the manufacturer; however, the parts were on back order. The contact became aware that the VIN was included in NHTSA Campaign Number: 22V413000 (Power Train). The manufacturer was notified of the failure but provided no assistance. The vehicle was not repaired. The failure mileage was approximately 100,070.

NHTSA ID

11470278

Incident

Jun 7, 2022

Mileage

100,070 mi

The contact owns a 2015 Ford Fusion Energi. The contact stated that the engine control module failed to shutoff the vehicle causing the battery to drain. The contact was then unable to start the vehicle. The failure happened several times over a two-year period. The contact stated that to restart the vehicle he would break into the vehicle through the trunk to get to the battery and jumpstart the vehicle. The contact had taken the vehicle to the dealer and was informed that there was no recall associated with the VIN and that there were no known issues. The contact stated that the manufacturer knew about the issue but decided not to issue a recall. The manufacturer was made aware of the failure and confirmed that there was no recall associated with the issue. The contact was referred to NHTSA for assistance. The approximate failure mileage of 96,000. Consumer found a website explaining exactly what was happening with consumer's car was found on lenberglaw.com lemon law vehicles.

NHTSA ID

11443137

Incident

Dec 8, 2019

Mileage

96,000 mi

TL* THE CONTACT OWNS A 2015 FORD FUSION ENERGI. WHILE THE VEHICLE WAS CHARGING, THE PLUG MELTED INTO THE WALL AT THE CONTACT'S HOME. THE CONTACT RECEIVED A RECALL NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 18V592000 (EQUIPMENT). THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE VEHICLE WAS TAKEN TO WEST HILLS FORD (1100 OYSTER BAY AVE S, BREMERTON, WA 98312) AND THEY STATED THAT THE PART WAS NOT AVAILABLE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

NHTSA ID

11186872

Incident

Sep 1, 2018

IF I CRANK THE CAR SOON AFTER CUTTING IT OFF, (WHILE IT'S STILL WARM) ENGINE SPUTTERS THEN QUITS, AS IF IT ISN'T GETTING ENOUGH FUEL. SO WHEN GETTING GAS, I HAVE TO HOLD DOWN THE GAS PEDAL OR ENGINE QUITS. AS SOON AS I START PUMPING, THE ENGINE STARTS CHOKING. I CAN'T TURN OFF THE IGNITION WHILE PUMPING GAS BECAUSE IT WON'T STAY CRANKED ONCE I TRY TO DRIVE AWAY UNLESS I REV THE RPM'S UP REALLY HIGH FOR A PERIOD OF TIME. I'VE HAD IT LOOKED AT SEVERAL TIMES AND NO ONE CAN FIGURE OUT WHAT'S WRONG. THIS HAS BEEN AN ONGOING PROBLEM FOR OVER A YEAR. AND NOW WHITE SMOKE BILLOWS OUT OF THE TAIL PIPE WHEN IT'S CRANKED. SECOND PROBLEM....ELECTRICAL. SOME OF THE STEERING WHEEL BUTTONS, SUCH AS CRUISE AND HANDS-FREE CALLING STOP WORKING OVER TIME. THIRD PROBLEM.... FRONT CV JOINTS WEAR OUT WAY TOO SOON. I HEARD OF A RECALL ON THE NEWS A COUPLE OF MONTHS AGO FOR MY CAR THAT SOUNDED LIKE MY ENGINE ISSUE, BUT NOW I CAN'T LOCATE THE RECALL ANYWHERE. THEY EVEN TOOK IT OFF OF THE NEWS CHANNEL'S WEBSITE. DURING THE BROADCAST, THEY SAID THE RECALL WOULD BEGIN DECEMBER 10TH. WHAT HAPPENED??? DID FORD CHANGE ITS MIND? SURE WOULD HELP ME OUT! I'M ENTERING THE OCCURRENCE DATE 1/1/17, BUT THIS HAS BEEN GOING ON WELL OVER ONE YEAR, MAYBE 2.

NHTSA ID

11162795

Incident

Jan 1, 2017

Mileage

50,000 mi

NHTSA RECALL 18V-592. FORD RECALL 18S24. CONVENIENCE CHARGE CORD REPLACEMENT. FORD HAS NOT PROVIDED A TIMELY RESOLUTION TO THIS RECALL AND HAS NOT PROVIDED A REASONABLE/PRACTICAL TEMPORARY SOLUTION TO CHARGING MY VEHICLE WITH A REPLACEMENT CORD THAT IS AVAILABLE, WITH A DIFFERENT PART # THAN MY CURRENT CORD. THE PART IS AVAILABLE BUT WOULD NOT BE HONORED UNDER THIS RECALL. THAT PART # IS HS7210B706A. IF THIS CHARGING CABLE IS AVAILABLE FOR MY CAR, THEN WHY CAN'T IT BE PROVIDED AT NO COST UNTIL THE REPLACEMENT CORD IS PROVIDED AT WHICH TIME, I CAN RETURN PART # HS7210B706A? PLEASE ADVISE THE BEST WAY TO PROCEED WITH OBTAINING A TEMPORARY CORD FOR CHARGING MY ELECTRIC VEHICLE OR AUTHORIZE OBTAINING PART #HS7210B706A AT NO COST.

NHTSA ID

11153693

Incident

Nov 20, 2018

SHIFTER BUSHING CABLE - THIS PART BROKE OFF FROM MY VEHICLE BACK IN JULY. THE BUSHING CONNECTS SHIFTER ARM TO TRANSMISSION. WITHOUT THIS PIECE, MY VEHICLE NEEDS ASSISTANCE TO COMPLETE EVERY SINGLE SHIFT. WHEN ATTEMPTING TO MOVE FROM PARK TO DRIVE, I HAVE TO GET OUT OF MY VEHICLE, OPEN THE HOOD, PLACE THE SHIFTER DOWN ON THE TRANSMISSION ARM, THEN SHIFT THE CART. TO GO FROM DRIVE TO PARK, I HAVE TO ENGAGE THE PARKING BREAK, GET OUT OF THE CAR, POP THE HOOD, REATTACH THE SHIFTER ARM, THEN SHIFT THE CAR. THIS ISSUE HAS BEEN ONGOING SINCE JULY 2018 WITH NO NOTICE FROM FORD ON WHEN THE REPLACEMENT PART WILL BE AVAILABLE. THIS SPECIFIC PART IS NOT SOLD ON THE AFTERMARKET EITHER, MEANING THAT I DO NOT HAVE ANY WAY TO FIX MY CAR AND THUS HAVE TO DEAL WITH THE ISSUE EVERY SINGLE TIME I DRIVE THE CAR. I'M VERY CONCERNED THAT ALL OF THIS SHIFTING AND OPENING AND CLOSING OF MY HOOD IS CAUSING LONG-TERM DAMAGE TO THE CAR (THAT FORD WOULD MOST LIKELY NOT FIX). I HAVE CALLED FORD OVER 8 TIMES TO COMPLAIN AND HAVE RECEIVED NO ETA ON PARTS, NO OTHER WAY TO FIX THE ISSUE, NOR ANY COMPENSATION/HELP TOWARDS ME BEING ABLE TO USE MY CAR. RECALL WAS ISSUED ON JULY 20TH, 2018; OVER 3 MONTHS LATER, NO REPLACEMENT PART HAS BEEN PROVIDED.

NHTSA ID

11144254

Incident

Jul 24, 2018

Mileage

100,000 mi

For 2015-2024 Ford and Lincoln vehicles equipped with turbocharged engines and customer concern of an engine oil leak, refer to Workshop Manual (WSM), Section 303-00 for oil leak inspection and testing methods. Ford has evaluated turbochargers replaced for oil leak symptoms and although oil may collect on the external surface of a turbocharger, it is extremely rare for a turbocharger assembly to be the root cause of the oil leak. Careful inspection of the turbocharger oil feed and drain tubes should be performed along with the recommended WSM procedures as needed. Warranty claims for turbocharger replacement going forward will be assessed.

Certain 2014-2020 Model Year Multiple Vehicle Lines 3G Telematics Control Unit to 4G Upgrade Kit REASON FOR THIS SUPPLEMENT Program Terms & Urgency / Expiration Date: Program extension until July 31, 2023. Service Action: o IDS level 128 or higher is now required to address various programming issues encountered. o C-MAX Energi vehicles are now serviceable with new software and hardware. Labor Allowances: C-MAX labor has been updated. Parts Requirements / Ordering Information: o The C-MAX 4G Upgrade Kit is now orderable at this time with a new part number. o MKX Rear seat backrest nut claim quantity updated. Technical Information updates: o Ensure IDS level 128 or higher is used. o Toggling Valet Mode is no longer required. o C-MAX Energi instructions are now available. Owner Notification: Non-repaired vehicle owners will be mailed the week of April 17, 2023. Pickup and Delivery: Added Customer Acknowledgement Form - Review form contents with customer prior to kit ordering and obtain customer signature prior to installation for Focus BEV, C-MAX, and Fusion Energi vehicles.

For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. Most modules on these affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are followed when diagnosing the condition prior to all module replacements and only order modules using the correct VIN.

Some 2014-2020 Fusion and 2017-2019 Escape vehicles may be equipped with a 1.5L Ecoboost engine that uses a 50-tooth variable camshaft timing (VCT) intake and exhaust unit from the assembly plant or if a service long block was installed. VCT locking tool 303-1097 is not compatible with this system. If VCT system service is required, replace both the intake VCT (service part DS7Z-6256-F) and exhaust VCT (service part DS7Z-6256-G) as a pair. An interim loaner tool program has been established to enable these repairs. Contact 1-800-403-4844 (Monday-Friday 8:00am to 8:00pm EST; Saturday 8:00am to 3:00pm EST) to obtain this tool. A VCT locking tool compatible with the 50-tooth system is under development and will be sent to dealerships. Continue to monitor OASIS for additional information.

Some Ford and Lincoln vehicles may exhibit noise when the brakes are applied. When diagnosing and repairing brake noise conditions, use the Workshop Manual (WSM) and the appropriate pinpoint test in section 206-00. The brake rotors should only be machined if directed by the WSM because one or more of the following conditions are present on the braking surface: scoring, excessive corrosion/rust or pitting, bluing/discoloration and/or heat spots. For additional information, refer to WSM section 206-00.

Some 2013-2016 Escape/Fusion/MKZ vehicles may display an error message when updating the All Wheel Drive-ATC Barcode using the IDS service function after installing a new rear drive unit assembly (RDU) or active torque coupling (ATC) clutch assembly. To prevent this error from occurring, enter the universal ATC 4 digit barcode 7772. Once programmed, perform several figure 8 turns at parking lot speeds to verify there is no binding from the all wheel drive (AWD) system. If the vehicle binds in a turn, perform Pinpoint Test A. Refer to the Workshop Manual (WSM), Section 308-07A > Diagnosis and Testing.