2018 Ford Fusion Energi

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.

Ford Fusion energi battery failure. Dealership wouldn't inspect the battery and kept replacing the battery control module. The replacement part kept failing under warranty and then the dealership quoted me $20,000 for the hybrid battery. They have replaced the BCM twice and error code P0dc9 keeps appearing. The EV range drops to zero randomly or gains range while parked and not plugged in. Dealership doesn't know what's happening even after paying money for diagnostics.

NHTSA ID

11742569

Incident

May 30, 2026

I routinely have plugged in my PHEV, enjoying the quiet electric ride. I could complete a day's commute with the electric charge. However, the battery capacity was significantly reduced at about 50K miles. At about 73K miles, within a couple miles of starting to drive, the car would decelerate and go into 'limp mode', with a top speed of 35MPH. A warning signal of a wrench would appear, indicating a power train fault. While diagnostics at the dealer didn't detect a cause, an emissions test required by the State of Colorado found an 'unstable Hybrid Battery A voltage'. I replaced the spark plugs as recommended by the dealer, but that didn't address the problem. The diagnostics and repair cost about $1000.00

NHTSA ID

11731934

Incident

Dec 6, 2025

The contact owns a 2018 Ford Fusion Energi. The contact stated that the hold voltage battery had decreased to 13–15 miles on a full charge when previously averaging 22–23 miles. There were no warning lights illuminated. The contact stated that the failure was related to Customer Satisfaction Program: 24N19. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and transferred the contact to the NHTSA Hotline. The failure mileage was approximately 80,000.

NHTSA ID

11667351

Incident

Jan 1, 2025

Mileage

80,000 mi

WHILE DRIVING AT 40 MPH, THE VEHICLE LOST POWER. THERE WERE NO WARNING INDICATORS ILLUMINATED PRIOR TO THE FAILURE. THE INFOTAINMENT SCREEN SYSTEM AND THE DASH CONSOLE DIALS ALL WENT COMPLETELY DARK. THE VEHICLE IMMEDIATELY SHUT DOWN WITH NO POWER IN THE MIDDLE OF THE ROAD. THE VEHICLE WOULD NOT START UP AGAIN. HOW CAN A VEHICLE BE DRIVING DOWN THE ROAD AND SUDDENLY AND WITHOUT WARNING GO "DARK" AND SHUT DOWN AND CANNOT BE START UP AGAIN? MULTIPLE CARS (MUCH OLDER CARS) HAD TO SWERVE AROUND MY BRAND NEW 2018 FORD FUSION ENERGI PLUG IN. THE VEHICLE IS AT THE DEALER AND IT IS AWAITING DIAGNOSTIC TESTING AND REPAIRS.

NHTSA ID

11218700

Incident

May 6, 2019

Mileage

12,000 mi

HAD CAR 1 YEAR WITH NO ISSUES, NOW ALL OF A SUDDEN THE SYNC 3 NAVIGATION SYSTEM KEEPS BREAKING. STARTED WITH GETTING A NO GPS SYMBOL IN THE BOTTOM LEFT CORNER OF THE NAVIGATION WINDOW. NOW SOMETIMES IT EFFECT THE RADIO, PHONE AND CLIMATE SYSTEMS BY REACTING REALLY SLOW TO ANY COMMANDS, IF IT DOES ANYTHING AT ALL. YOU CAN PUSH A BUTTON AND WAIT OVER A MINUTE FOR A COMMAND TO BE EXECUTED SOMETIMES. OTHER TIMES, GET IN CAR, EVERYTHING IS FINE, BUT EVENTUALLY THE NO GPS SYMBOL WILL COME BACK ON, AND ALL ACCESSORIES WILL WORK FINE, OTHER TIMES THEY GO INTO SLOW MOTION. TOOK TO DEALER AT 13 MONTHS AND APPROX. 15K MILES, THEY SAID IT NEEDED AT SOFTWARE UPDATE. WORKED GREAT UNTIL WE GOT HOME AND THE NO GPS SYMBOL CAME ON AS WE REACHED HOME. TOOK BACK IN, THEY SAID IT NEEDED A NEW COMPUTER BRAIN FOR THAT SYSTEM, BUT ITS ON NATIONAL BACKORDER. IT ENDED UP COMING IN A WEEK LATER, TOOK CAR IN 2 WEEKS LATER AND EVERYTHING WAS FAST AGAIN AND WORKING IN DEALER PARKING LOT AS WE SET UP THE CONTROLS FOR PHONE, ETC AGAIN. NEXT MORNING, THE NO GPS SYMBOL CAME ON AGAIN. LATER THAT DAY, RADIO WOULD NOT RESPOND TO BUTTONS PUSHED OR COMMANDS THROUGH VOICE FROM STEERING WHEEL CONTROLS. NEXT DAY, STILL SAME PROBLEMS WITH GPS. HAVE YET A FOURTH APPOINTMENT TO TAKE IT IN NOW, (FIRST WAS SOFTWARE UPGRADE, SECOND TO SAY IT NEEDED NEW COMPUTER, THIRD TO REPLACE COMPUTER, NOW FOURTH BECAUSE ITS STILL NOT WORKING) GETTING FED UP WITH PAYING ALL THIS MONEY FOR THE TOP OF THE LINE FUSION ENERGI AND HAVING THIS ISSUE THAT IS STILL NOT FIXED AND HAVING TO KEEP TAKING IT IN.

NHTSA ID

11191254

Incident

Mar 24, 2019

Mileage

17,000 mi

I PULLED UP TO THE GARAGE DOOR STOPPING TO PRESS THE REMOTE BUTTON TO OPEN THE DOOR (AS I DO EVERY DAY). SUDDENLY THE CAR LURCHED FORWARD IN THE BUILDING DAMAGING THE DOOR POST AND THE FRONT OF THE CAR. WHEN I SAW THE BUILDING COMING CLOSER I HAD SLAMMED THE BRAKE AS HARD AS I COULD.

NHTSA ID

11081229

Incident

Mar 23, 2018

Mileage

1,231 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.

During service and repair requiring removal and replacement of a crankshaft bolt and/or crankshaft damper, achieving proper torque of the crankshaft pulley bolt is critical. Incorrect torque may allow the bolt to loosen resulting in the timing gear breaking and engine damage. Replacement of the bolt is critical to the repair and accurately following the installation procedure in the Workshop Manual (WSM) Section, 303-01 is extremely important. The bolt torque procedure can be found in the crankshaft front seal removal and installation procedure or in the engine assembly procedure.

In various 2017-2023 Ford and Lincoln vehicles, customers may receive a message in the FordPass or LincolnWay App stating Feature Unavailable. Since this is a fleet vehicle, it cannot access the (SYNC Connect) FordPass or LincolnWay app through the TCU Embedded Modem. If this message appears, the vehicle may be equipped with a fleet telematics module. Replacement of the TCU or TCU related repairs will not prevent this message from appearing. Refer the customer to in app FordPass Guides or LincolnWay Concierge Teams to aid with fleet telematics removal. Open app, select Account > Help > CHAT or CALL option.

The Service Awareness Newsletter is an informal communication that contains information that may not be presently available in a TSB, SSM, GSB, or other electronic communication. This article includes information on warranty, technical service tips and other service information.

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.