2010 Ford Fusion Hybrid

The Office of Defects Investigation (ODI) received a petition on December 22, 2025, requesting a defect investigation into the hydraulic control unit (HCU) for the Anti-lock Braking System (ABS) on the MY 2010 Ford Fusion Hybrid. The petition alleges that an illuminated ABS MIL is associated with a failure of the ABS HCU, resulting in ABS malfunction, loss of traction and electronic stability control functions, and reduced braking performance, particularly on slippery road surfaces. ODI conducted an analysis of complaints submitted to ODI for the subject vehicle population along with data submitted by Ford.  The Petitioner alleged that the condition in the subject vehicles was comparable to the defect addressed by NHTSA recall No. 19V904, which covered certain MY 2006-2010 Ford Fusion, Mercury Milan, and Lincoln MKZ vehicles.  The population of this recall consisted of the non-hybrid variants of these models. The recall addressed a defect where the ABS valves in the HCU could remain stuck open due to a chemical reaction with aged DOT 3 brake fluid, potentially causing extended brake pedal travel and increasing the risk of a crash.   DOT 3 brake fluid is a conventional, glycol-ether-based hydraulic fluid used to transfer force from the brake pedal to a vehicle's brakes.  No visual or audible warning was presented to the driver in this scenario. The MY 2010 Ford Fusion Hybrid is equipped with a different brake apply system in which the traditional hydraulic (friction) brakes are blended with the hybrid regenerative brake system.  In this system, the brake master cylinder is electrically activated and provides force feedback through the brake pedal to the driver.  Unlike the recalled models, Petitioner’s 2010 Ford Fusion Hybrid would not experience the same defect, as a stuck-open normally closed valve within its ABS HCU does not result in increased brake pedal travel.  This condition is further supported by the relative complaint rates in the two populations: ODI found the complaint rate of the recalled MY 2010 Fusion vehicles was six times higher than that of the subject MY 2010 Fusion Hybrid vehicles, which supports a significant difference in the design and performance of the brake system and components. As the Petitioner stated, most of the subject hybrid vehicle VOQs cited an illuminated ABS MIL.  The vehicles in 19V904 did not present the driver with an illuminated MIL or associated diagnostic trouble code (DTC).  Since the MY 2010 Ford Fusion Hybrid presented with a brake MIL, the failure mode differs from that of the non-hybrid population, which did not trigger an illuminated warning light. Additionally, given the age of the subject vehicles (MY 2010), the low complaint volume is consistent with expected wear and tear rather than an actionable safety defect trend. For the above reasons, ODI is denying this Defect Petition as it has not found an unreasonable risk to highway safety.  The Agency reserves the right to take additional action if warranted by future circumstances.  To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

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.

On September 28, 2016, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE16-011) to investigate claims of power steering assist loss on model year (MY) 2010 Ford Fusion vehicles.  During the PE, ODI received 718 unique claims related to the alleged problem with 598 reports indicating the power steering assist failed while driving at various speeds with no warning.  Ford Motor Company (Ford) provided 1,851 unique reports and 1,720 warranty claims related to the alleged problem.  It should be noted that as the result of investigation PE14-030, Ford conducted a safety recall (15V-340) ofMY 2011-2012 Ford Fusion and other vehicles using the same electric power assist steering unit to rectify incidents of loss of power steering assist. On November 20, 2017, PE16-011 was upgraded to this Engineering Analysis (EA17-004) to further assess the scope, frequency, and consequence of this failure.  This was based on an analysis of the subject vehicle complaint data that had indicated an increased likelihood of failure as the vehicles age.  At the time, the rate of occurrence of this failure was comparable to previous investigations involving loss of power steering assist including the previously mentioned PE14-030. During the EA, ODI’s analysis of the alleged defect in the subject vehicles identified the following:  testing showed minor steering effort changes between “assist” and “no assist”, no root cause identified, a declining failure trend, the ramp-down or reduced assist provided when a DTC is set, a lower failure rate than the recalled Fusion vehicles, and the high age of the vehicles. A safety-related defect trend has not been identified.  Accordingly, this Engineering Analysis is closed.  See the attached Engineering Analysis Closing Report for details.  The closing of this investigation does not constitute a finding by NHTSA that a safety defect does not exist, and ODI will take further actions if warranted by future circumstances.  To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

On September 28th, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation PE16-011 to investigate claims of power steering assist loss on model year 2010 Ford Fusion vehicles.ODI has received 718 unique claims related to the alleged problem with 598 reports indicating the power steering assist failed while driving at speed with no warning.During the PE16-011 investigation, Ford Motor Company (Ford) provided 1851 unique reports and 1720 warranty claims related to the alleged problem.As the result of investigation PE14-030, Ford previously conducted a recall (15V-340) of the 2011-2012 Ford Fusion and other vehicles using the same electric power assist steering unit to rectify incidents of loss of power steering assist.An analysis of the subject vehicle complaint data indicates an increased likelihood of failure as the vehicles age.The rate of occurrence of this failure is comparable to previous investigations involving loss of power steering assist including the previously mentioned PE14-030.Therefore, the Preliminary Evaluation (PE16-011) has been upgraded to an Engineering Analysis to further assess the scope, frequency and consequence of this failure. ODI reports cited above can be reviewed at https://www.nhtsa.gov/recalls#vehicle under the identification (NHTSA ID) numbers found in the attached list.

The contact owns a 2010 Ford Fusion Hybrid. The contact stated that while driving, the ABS warning light remained illuminated, and the Service AdvanceTrac warning message remained displayed. In addition, when depressing the brake pedal to come to a complete stop, the brake pedal extended to the floor, resulting in an extended stopping distance. The contact engaged the parking brake to bring the vehicle to a stop. The vehicle was taken to an independent mechanic, where it was diagnosed that the ABS control module had failed and required replacement. The manufacturer was notified of the failure; however, no assistance was provided. The contact associated the failure with NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic). The failure mileage was 210,000.

NHTSA ID

11772393

Incident

Aug 1, 2025

Mileage

210,000 mi

I own a 2010 Ford Fusion Hybrid. The vehicle has a recurring loss-of-braking problem associated with the ABS/ AdvanceTrak system. While driving, the vehicle can suddenly lose normal braking ability and does not stop as it should when I press the brake pedal. The ABS, AdvanceTrak, traction control/hydroplaning and other warning lights illuminate at the same time. I have had to use the emergency/parking brake to help stop the vehicle.The exact underlying component causing the failure is UNKNOWN. The ABS module/ ABS hydraulic control unit (HCU) has been diagnosed and replaced more than once, and the vehicle has also been repeatedly reprogrammed and diagnostic codes cleared. The vehicle has been inspected by three different Ford dealerships for the same recurring problem. The dealerships have performed diagnostic work and repairs, including replacement of ABS-related components. Most recently, 1 paid approximately $1,600 to a Ford dealership for an ABS-related repair. I was told the vehicle was repaired and picked it up on [10-6-26]. Less than 24 hours later, while driving, the vehicle again lost normal braking ability. The same warning lights appeared, including ABS and Service AdvanceTrak, and I again had to use the emergency/parking brake to stop. The vehicle is available for inspection upon request. The recurring loss of braking creates a serious safety risk to me and other road users because the vehicle may not stop normally when the brake pedal is applied. I have not had a crash or injury from this failure, but I have had to take emergency action to avoid one.The warning lights and symptoms have occurred repeatedly before and after repairs. Previous Ford dealerships have diagnosed and attempted to repair the problem, but the failure continues to return. The most recent failure occurred less than 24 hours after the last repair.

NHTSA ID

11769526

Incident

Oct 7, 2026

I own a 2010 Ford Fusion Hybrid and am reporting a recurring and serious braking problem. On XXX, while driving to pick up my mom and my [XXX] son, I pressed the brake pedal to stop, but the vehicle did not stop normally. I repeatedly tried to brake, but the vehicle took much longer to stop than it should have. The brake pedal became spongy and did not have normal resistance. The BRAKE, ABS, and AdvanceTrac warning lights appeared. The vehicle’s computer/system was reset afterward, and the vehicle drove normally for several days. On XXX, the same braking problem happened again while i was driving to go pick up my [XXX] son from school. The brake pedal became spongy, and repeatedly pumping the brakes did not properly stop the vehicle. This time I had to use the emergency/parking brake to help bring the vehicle to a stop. The same BRAKE, ABS, and AdvanceTrac warning lights appeared.After this incident, the rear brakes were replaced and a new ABS Anti-Lock Brake Pump (part number 9E58-2C555-AF) was installed. The computer/system was also reset again. On XXX, the BRAKE, ABS, and AdvanceTrac warning lights came back on again despite the new brake components and computer reset. The mechanic who performed the repairs has been unable to determine the cause, so the vehicle is being taken to another repair shop for further diagnosis. I am concerned that this may be a safety defect involving the braking/ABS system of the 2010 Ford Fusion Hybrid. The vehicle has experienced an actual loss of braking ability, including an incident where I had to use the emergency/parking brake to stop. I am requesting that NHTSA investigate this issue. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11763255

Incident

Aug 26, 2026

2020 Ford Escape wipers keep stuttering, moving very slowly, freezing midway through cycle, or fail to operate during adverse weather conditions. This results in poor to no visibility sometimes with the wiper blocking vision directly. This is a known recall and Ford has refused to repair the wiper until the unveil their solution for all potentially impacted vehicles. They acknowledge that a wiper motor would repair our vehicle right now but told us to wait for months while they determine a global fix. Recall number we believe is 26S14. Both Ford America and local dealer will not perform work. Communications were via phone call with both dealer and Ford America.

NHTSA ID

11757251

Incident

Aug 8, 2026

The power steering has failed twice recently while driving and the dashboard warning displayed as follows: power steering assist fault. This makes it very hard to steer, dangerous and scary when this happens. Can a recall be issued for my vehicle? I am very disappointed that my 2010 ford fusion hybrid vehicle was left out of the recall even though it was manufactured at the same plant as the 2011 - 2013 models that were recalled. I found this online: Investigation and Recall ContextFederal Probes: The NHTSA investigated 2010–2012 Ford Fusion and Lincoln MKZ models for sudden loss of electric power steering, logging thousands of complaints.Exclusion of the 2010 Model: Ford issued recalls (such as campaign 15S18) for 2011–2013 models to update power steering control modules or fix motor sensor faults, leaving 2010 models uncovered by the official action.Closure: The NHTSA officially closed its investigation into the 2010 Fusion steering complaints after concluding the failure trend did not warrant a mandatory safety recall, noting drivers could still revert to manual steering.

NHTSA ID

11757063

Incident

Aug 14, 2026

SUBJECT: Fraudulent Recall Completion / Incomplete Remedy resulting in Component Failure (Recall 19S54 / NHTSA 19V904) I am writing to file an emergency safety complaint regarding a fraudulently cleared safety recall on my 2010 Ford Fusion Hybrid. According to Ford's internal OASIS database, Safety Recall 19S54 (NHTSA Campaign 19V904) was marked as "completed" under a previous owner. However, physical inspection of the vehicle proves that the mandatory federal remedy was never executed. The master cylinder still retains the original factory DOT 3 cap, and the system was never upgraded to DOT 4 fluid. Because the servicing dealership falsified the repair documentation and left the corrosive DOT 3 fluid in the system, my vehicle has now suffered the exact catastrophic safety failure the recall was meant to prevent. The ABS Hydraulic Control Unit (HCU) internal valves have seized. The brake pedal is heavily compromised, and the vehicle is an active, severe safety hazard to drive. I am the second owner of this vehicle. I unknowingly purchased a car with a fraudulently cleared safety defect. Because this failure is a direct result of an incomplete federal safety recall remedy, I demand that Ford Corporate reopen this VIN file under "Related Damage / Incomplete Remedy." I require Ford to: 1. Arrange a complimentary tow to a certified Ford dealership. 2. Replace the ruined ABS/HCU module entirely free of charge. 3. Perform the mandatory DOT 4 pressure flush and install the correct reservoir cap. 4. Provide a complimentary rental car while this safety hazard is being resolved. I have taken photographic and video evidence of the DOT 3 cap and the failed braking system to support my legal claims. Fairway Ford of Yorba Claimed it had already been done when clearly it hasn't and pushed it off like nothing.

NHTSA ID

11753024

Incident

May 18, 2026

Abs module failed

NHTSA ID

11748073

Incident

May 5, 2026

There have been many recalls on the 2010 Ford Fusion Hybrid, according to Ford mine has already had the repairs done yet the issues I’ve been having all match recalls. I’ve had issues with my passenger seat, the air bag system light is always on and the seat controls no longer work. The clockspring system is pure trash, there is no reason I’ve had to replace it twice now in the 2 months I’ve had this car. My ABS system keeps going in and out and says service advancetrac system. My hybrid battery rarely goes into hybrid anymore causing my mpg to drop. There were a few other things but that’s what’s coming out mind now.

NHTSA ID

11744392

Incident

May 20, 2026

When performing any transmission fluid change or topoff involving Motorcraft® Premium ATF, MERCON® V has replaced all versions of Motorcraft® Premium ATF and can be used going forward. Mixing Motorcraft® Premium ATF and MERCON® V in the same transmission is acceptable. After 31-Jan-2024, Motorcraft® Premium ATF will no longer be manufactured and will only be available until inventory depletes.

Some 2010-2012 Fusion/Milan and 2011-2012 MKZ vehicles equipped with a 2.5L or 3.0L engine and electronic power assist steering (EPAS), a remanufactured replacement steering gear (MU2Z-3V504-ARM) is available which is significantly less expensive than a new replacement gear. When conducting repairs that are customer pay, offer the customer a remanufactured gear when possible. This would include vehicles not included in field service action (FSA) 15N01 (built on or before 7-Sep-2010) or vehicles included in FSA 15N01 that have exceeded the 10 year/150,000 mile terms of the program.

Some 2010-2012 Fusion hybrid electric vehicles (HEV), 2010-2011 Milan HEV and 2011-2012 MKZ HEV vehicles may experience reduced electric vehicle operation and increased gasoline engine operation around 10 years of vehicle age and beyond. This may be due to software in the battery energy control module (BECM) and the powertrain control module (PCM). To correct the condition, follow the Service Procedure to reprogram the BECM and PCM.

Certain 2010 – 2012 Model Year Fusion / MKZ / Milan Hybrid Vehicles Hybrid Battery Reduced Electric Vehicle Operation BECM and PCM Software Update In all the affected vehicles, outdated software may result in reduced EV-only mode performance earlier in the life of the vehicle than intended.

Certain 2005-2014 Mustang, 2005-2006 GT, 2004-2011 Ranger, 2006-2012 Fusion & MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge & MKX Vehicles Driver & Passenger Airbag Module Quality Control Inspection: Ford Motor Company has determined that some vehicles claimed by dealers as repaired under Takata Airbag Safety Recalls 15S21, 17S42, 18S02, 19S01, and 21S12 may not have received the claimed repairs. The propellant in certain Takata airbag inflators can experience an alteration over time with exposure to certain climate conditions. A combination of time, high temperature fluctuations, and humidity contribute to the degradation of the propellant in the inflators. This degradation can cause the propellant to burn too quickly, creating high pressure inside the inflator, and in extreme cases causing the inflator to rupture in the event of a crash necessitating airbag deployment. A ruptured inflator can send inflator parts toward vehicle occupants resulting in serious injury or death. Additional information regarding Takata recalls can be found at www.nhtsa.gov and www.safercar.gov.

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended.