2016 Ford Fusion Hybrid

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.

On August 8, 2022, the Office of Defects Investigation (ODI) opened this investigation based on 50 Vehicle Owner Questionnaires (VOQs) alleging front brake jounce hose ruptures on model year (MY) 2013-2018 Ford Fusion and Lincoln MKZ vehicles. A ruptured front brake hose results in a brake fluid leak. As a result, the driver may experience an increase in pedal travel and a reduction in the rate of deceleration, increasing the risk of a crash. It should be noted that the subject vehicles identified fell outside the scope of NHTSA Safety Recall 20V-469, which addressed front brake hoses rupturing on certain MY 2015-2018 Ford Edge and 2016-2018 Lincoln MKX vehicles. The result causes a brake fluid leak, lengthening the distance needing to stop the vehicle, increasing the risk of a crash.On March 10, 2023, Ford Motor Company (Ford) submitted to NHTSA Safety Recall 23V-162 (Ford Recall 23S12) to address front brake jounce hoses that may rupture. Ford found the rupture occurs from a localized failure of the internal reinforcement braid due to cyclic fatigue through tensile/bending and torsional inputs during suspension and steering articulations. The supplier for the front brake jounce hoses is Hitachi. This recall affects the subject vehicles equipped with non-hybrid engines and the suspect front brake jounce hoses (a total of 1,280,726 vehicles). The recall covers subject vehicles built from February 3, 2012 to July 19, 2017 when the suspect hoses were used in vehicle production. The remedy is for dealerships to replace both front brake jounce hoses with new hoses that have a revised braid material at no cost. The vehicles equipped with hybrid engines are excluded from the recall because the internal hose pressure is much lower due to the regenerative braking provided by the hybrid brake system. No failures of brake hoses on hybrid vehicles have been reported to ODI or Ford.Ford's actions address ODIs concerns at this time. Hybrid vehicles will be monitored for related failures. The agency reserves the right to take further action if warranted by new circumstances.The 103 ODI numbers cited above can be viewed at NHTSA.gov under the following ID numbers:11511014, 11510867, 11510318, 11509030, 11505993, 11504989, 11504400, 11502147, 11502082, 11501820, 11501283, 11498439, 11498296, 11496842, 11496335, 11494931, 11494851, 11494252, 11493001, 11492084, 11492070, 11491444, 11491274, 11488858, 11488027, 11487627, 11487416, 11487233, 11486150, 11484924, 11484526, 11484080, 11483948, 11483926, 11483739, 11483723, 11482773, 11482690, 11481077, 11480788, 11480294, 11480052, 11479338, 11479334, 11479252, 11479247, 11479187, 11479094, 11479048, 11478985, 11478953, 11478729, 11478216, 11476892, 11476282, 11470558, 11468994, 11467109, 11466294, 11462746, 11461217, 11456065, 11455367, 11444848, 11436419, 11436376, 11430685, 11428329, 11425083, 11421026, 11420738, 11420735, 11420298, 11418197, 11403926, 11397549, 11366991, 11366757, 11361016, 11359968, 11354569, 11352165, 11350344, 11348799, 11343929, 11343205, 11331947, 11329020, 11319596, 11310529, 11292271, 11288455, 11254787, 11253479, 11253244, 11234622, 11230669, 11230050, 11228240, 11221111, 11143630, 11129392 and 11120228.

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

I am submitting this complaint regarding an unrepaired safety recall on my 2016 Ford Fusion, Ford Recall 25SA9 / NHTSA Recall 25V695, involving the rear-view camera. The recall concerns a condition where the rear-view camera may display a blank or distorted image when the vehicle is placed in reverse. This can reduce the driver's ability to see what is behind the vehicle and increase the risk of a crash. The recall was issued in October 2025. I have been waiting for the recall remedy to become available, but Ford and the dealership have been unable to complete the repair because the necessary parts are not available. As of August 11, 2026, my vehicle's NHTSA recall status still states: "Recall Incomplete, remedy not yet available." This means that approximately 10 months after the recall was issued, I still do not have access to the recall repair for a known safety defect. I understand that parts shortages can occur; however, I am concerned that such a significant amount of time has passed without Ford providing a remedy. The recall information indicates that the remedy was expected to become available, yet my vehicle remains unrepaired. I am requesting that NHTSA review Ford's handling of this recall and determine: Why the recall remedy remains unavailable approximately 10 months after the recall was issued. When Ford expects the required repair parts to actually become available. Whether Ford is taking adequate steps to provide affected vehicle owners with a timely and effective remedy. Whether Ford has provided an adequate interim solution for owners while they wait for the repair. I have contacted the dealership regarding the recall and have been advised that they cannot complete the repair because the necessary parts are unavailable. I am requesting NHTSA's assistance and review because this is a safety recall that remains unresolved many months after being issued. Vehicle: 2016 Ford Fusion Manufacturer Recall: 25SA9 NHTSA Recall: 25V695 Defect: Re

NHTSA ID

11756279

Incident

Oct 1, 2025

EVAP blocking valve failed and car immediately went into limp mode on the highway. By doing this it could cause a crash. EVAP blocking valve also should last the life of the vehicle.

NHTSA ID

11696645

Incident

Oct 28, 2025

The contact owns a 2016 Ford Fusion Hybrid. The contact stated while driving at an undisclosed speed, the steering wheel was turned; however, the steering wheel failed to turn in the intended direction. In addition, the contact stated that the trunk latch was independently unlocked. The contact stated that the trunk failure had started in 2023. The vehicle was towed to an independent mechanic where it was diagnosed with a failed rack and pinion. The contact was informed that the rack and pinion needed to be replaced. The vehicle was in the process of being repaired. The manufacturer was made aware of the failure but provided no assistance. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 123,000.

NHTSA ID

11646723

Incident

Mar 6, 2023

Mileage

123,000 mi

The contact owns a 2016 Ford Fusion Hybrid. The contact stated that after the vehicle was parked, the contact’s husband exited and closed the front passenger's side door; however, the front passenger's side door latch fractured and failed to properly close the door. The contact stated that there was no impact to the front passenger's side door that could have caused the door latch to fracture. The contact had to firmly push the front passenger's side door to keep the door closed. The vehicle was taken to an independent mechanic, who determined that the front passenger's side door latch needed to be replaced. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 23V775000 (Latches/Locks/Linkages); however, the VIN was not included in the recall. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 143,000.

NHTSA ID

11605331

Incident

Jul 15, 2024

Mileage

143,000 mi

Car has intermittent electrical issue that causes ECUs to reboot often times disabling safety systems such as ABS, Airbags, Collision Avoidance, Adaptive Cruise Control, power steering and power brakes. Ford dealer believes that it's a short in a wiring harness. They claim this issue has been seen in several vehicles like mine. Ford was able to reproduce the problem and recommends replacement of a wiring harness ($4k). To date, I have not had an accident, but do not feel safe driving the vehicle if the airbags and other safety systems become inoperable. Yes, all of the dashboard lights come on when this issue occurs - technician states that the whole computer system gets taken down. That's very uncomfortable when you are traveling at highway speed and no longer have safety system. Steering and braking do get impacted but are not inoperable. I can provide videos of the dashboard when these events occur.

NHTSA ID

11574928

Incident

Nov 27, 2021

Transmission in vehicle causes erratic engine behavior and has a grinding sounds

NHTSA ID

11551231

Incident

Aug 23, 2022

My 2016 Fusion Hybrid SE. All SYNC related functions ceased to function . Cant use bluetooth. cant do voice commands. USB is not working and not charging. Radio works fine, but phone button does nothing; menu button does nothing; voice command button on steering wheel does nothing. This is a safety hazard and I know I'm not the only one having this issue.

NHTSA ID

11545899

Incident

Sep 1, 2023

The contact owns a 2016 Ford Fusion. The contact stated while reversing, the back prevention camera display screen went blank and the warning message saying, "back camera unavailable contact the dealership." The vehicle was not diagnosed. The vehicle was not repaired. The manufacturer was contacted and stated that there was no recall for the failure and did not provide any assistance. The failure mileage was 55,000.

NHTSA ID

11536569

Incident

Jun 4, 2021

Mileage

55,000 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.

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.

Some 2013-2020 Fusion, MKZ and 2013-2018 C-Max vehicles equipped with an HF35 transmission may exhibit a thumping/rubbing or grinding noise coming from the transmission. The noise may be present in all gear ranges including neutral when the vehicle is moving but will not be present when the vehicle is stationary or in park.