2016 Ford Fusion Energi Electrical Problems

I am filing this complaint concerning my 2020 Ford Fusion Energi and Ford Safety Recall 23S33 / NHTSA Recall 23V440 involving the high-voltage battery. Ford's recall notice states that the Battery Energy Control Module may become damaged due to excess voltage and current flow caused by a Current Interrupt Device activation in one or more high-voltage battery cells. Ford states that this can result in loss of motive power or a vehicle fire. My vehicle has been subjected to the recall remedy/interim work and I cannot use its plug-in charging capability. I purchased this vehicle specifically as a plug-in hybrid. Ford's May 2026 recall notice states that Ford authorized dealers to replace the high-voltage battery free of charge and that the repair will restore plug-in charging functionality. However, I have subsequently been informed that a replacement battery may not actually be available for my vehicle until approximately XXX, and I have been told that even that estimated timeframe is not guaranteed. I purchased this vehicle used at approximately 37,000 miles and it currently has only approximately 43,705 miles. I have therefore driven it only approximately 6,705 miles since purchasing it. My concern is that Ford acknowledges a safety-related high-voltage battery defect and has restricted the plug-in capability of the vehicle, yet I may potentially have to wait until late 2027 or longer for the replacement battery that restores the vehicle's intended functionality. I am requesting that NHTSA review Ford's administration of Recall 23S33 as it relates to the availability and timeliness of the permanent high-voltage-battery remedy and determine whether owners such as myself are receiving a safe, free and effective recall remedy within an appropriate period. I was working in [XXX] and did not receive recall information at my [XXX] address I am back in [XXX]. I want Ford to buy back the vehicle based on the letter sent. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11768038

Incident

May 1, 2025

The contact owns a 2016 Ford Fusion Energi. The contact stated while reversing at 5 MPH, the rearview camera failed to respond. There were no warning lights illuminated; however, there was a message displayed that the rearview camera would stop working while in reverse, and to please contact the dealer if the camera failed to operate as needed. The failure was intermittent. The vehicle was not taken to be diagnosed or repaired. The contact stated the radio intermittently failed to operate as needed. The dealer was not made aware of the failure. The manufacturer was not made aware of the failure. The failure mileage was approximately 105,000.

NHTSA ID

11654840

Incident

Oct 1, 2024

Mileage

105,000 mi

On 9/5/2024, the driver (27/M) and lone occupant was found unresponsive in the vehicle which was observed rolling to a stop. The vehicle impacted a chain link fence at low speed and there was minimal damage to the vehicle. First responders commented: "extremely noxious odor, smelling like burnt eggs was detected. Odor was most prevalent in backseat area and then when the trunk was opened. In the trunk is where the vehicle's hybrid battery system was located". The driver was transported to a local hospital and was pronounced dead on 9/5/2024. An autopsy was performed with toxicological analysis. Hydrogen sulfide was detected.

NHTSA ID

11636247

Incident

Sep 5, 2024

TL* THE CONTACT OWNS A 2016 FORD FUSION ENERGI. THE CONTACT STATED THAT THE DEFROSTER AND WINDOWS WERE INOPERABLE AND PROVIDED LOW VISIBILITY. IN ADDITION, THE CHECK ENGINE, SIDE IMPACT, AND ELECTRONIC MALFUNCTION WARNING INDICATORS WERE ILLUMINATED. THE VEHICLE WAS TAKEN SEVERAL TIMES TO ROBERTS MOTORS, INC. (4350 N ALBY ST, ALTON, IL 62002, (855) 999-5497) WHERE IT WAS DIAGNOSED THAT THE COMPUTER MODULE AND WIRING NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED. THE MANUFACTURER WAS CONTACTED AND DID NOT ASSIST. THE FAILURE MILEAGE WAS 45,000.

NHTSA ID

11290143

Incident

Dec 1, 2018

Mileage

45,000 mi

TL* THE CONTACT OWNS A 2016 FORD FUSION ENERGI. WHILE ATTEMPTING TO PULL THE ELECTRICAL CHARGER OUT OF THE VEHICLE, THE CHARGER WAS EXTREMELY HOT. THE CHARGER BURNED THE CONTACT'S HAND. THERE WERE NO INJURIES THAT REQUIRED MEDICAL ATTENTION. THE CONTACT DROPPED THE CHARGER AND IT LANDED ON THE REAR DRIVER'S SEAT AND BURNED A HOLE IN THE SEAT. THE VEHICLE WAS TAKEN TO KEN GARFF FORD (597 E 1000 SOUTH, AMERICAN FORK, UT 84003), BUT THEY WERE NOT ABLE TO DETERMINE WHY THE CHARGER BECAME SO HOT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 47,000.

NHTSA ID

11267042

Incident

Oct 22, 2018

Mileage

47,000 mi

CENTER CONSOLE BECOMES NON-RESPONSIVE WITH BUTTONS. A/C LOSSES CONNECTION AND WINDOWS GET LOCKED INTO POSITION AS WELL AS POWER SEATS. HAPPENS INTERMITTENTLY. MORE COMMON WHEN IT GETS REALLY HOT OUT.

NHTSA ID

11218282

Incident

Jun 5, 2019

Mileage

41,000 mi

FORD FUSION ENERGI, DID ITS LOW POWERED STATE AGAIN, THIS TIME ON THE FREE WAY, DROPPING RAPIDLY FROM 75MPH TO 22MPH AND BARELY ABLE TO MAINTAIN THAT SPEED. THE DISPLAY SHOWED THE SAFETY FEATURES BECOMING DEACTIVATED. SOMETHING NEW THOUGH, THE HEADLIGHTS WENT OUT AND THE CONSOLE DIMMED AND WAS BARELY READABLE, I TURNED ON MY HAZARDS AND I HOPE THEY WHERE WORKING, EITHER WAY I WAS FORTUNATE ENOUGH TO AVOID A REAR END COLLISION AND GOT THE VEHICLE OFF THE ROAD. THIS ABOUT 7TH TIME FORD WILL WORK ON THE VEHICLE, AND ANOTHER WEEK OR MORE WITHOUT A VEHICLE, WAITING FOR THE NEXT AVAILABLE APPOINTMENT. THESE FUSIONS ARE BECOMING THE NEW FORD PINTO. I REALLY HOPE THAT SEVERAL PEOPLE DON'T HAVE TO DIE, BEFORE FORD IS FORCED TO RECALL THESE DEATH TRAPS.

NHTSA ID

11151336

Incident

Nov 8, 2018

Mileage

19,000 mi

1) FIRST ISSUE HAPPENED 2/20/2017 ODOMETER 7,036. DASHBOARD LIT UP, TRAC CONTROL, ENGINE LIGHT, BRAKE, MESSAGE TO PULL OVER, LOSS OF POWER AND AT FREEWAY SPEED, GOT OVER SHOULDER SAFELY. THE ONBOARD DIAGNOSTICS SYSTEM DETECTED ENGINE MISFIRE, TRANSMISSION RELATED PROBLEMS. BROUGHT IT IN FOR SERVICE AND COULDN'T DUPLICATE ISSUE. NOTHING FIXED OR REPAIRED 2) SECOND TIME SAME ISSUE HAPPENED 7/21/2017 ODOMETER 15,736 GOING UP A HILL WEST BOUND ON MCCALL, LOSS OF POWER AND ALMOST GOT REAR ENDED BY A COUPLE OF VEHICLES. VEHICLE IS IN SERVICE AS I FILL THIS OUT.

NHTSA ID

11010265

Incident

Jul 21, 2017

Mileage

15,735 mi