2010 Ford Fusion

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.

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 Office of Defects Investigation (ODI) opened a preliminary evaluation to investigate complaints of the loss of power steering while driving. The subject vehicles are equipped with a rack mounted Electric Power Assisted Steering (EPAS) unit.Some of the complaints alleged that the steering assist failed and resulted in increased steering efforts that contributed to a loss of control and in some cases a crash.The EPAS system was manufactured by TRW Automotive for Ford and was designated as Generation I.These units were first produced and put into vehicle production in July 2008 beginning with the model year (MY) 2010 Ford Fusion and Mercury Milan.The system is comprised of a mechanical steering rack-and-pinion gear with torque sensor, electric assist motor, motor position sensor and a power steering control module (PSCM). The PSCM is self-monitoring and designed to detect faults within the system and can store diagnostic trouble codes (DTCs) if a problem is detected.There are 29 potential DTCs the system can detect.Many of these allow the system to go into reduced-assist steering mode by using the default vehicle speed signal should the live speed signal be lost, if voltage to EPAS system falls below 10.7 or goes above 17 volts, the temperature at the PSCM goes above 105C (221F), or if high friction is detected.Some DTCs will cause the system to go into manual steering mode (no assist). On July 1, 2015, Ford filed a Defect Information Report (DIR) identifying a safety related defect in TRW GEN I EPAS systems installed in some of the subject vehicles (NHTSA Recall 15V-340, Ford No. 15S18).The DIR indicated that intermittent electrical connections caused by quality issues associated with conformal coat contamination and ribbon cable pin misalignment within the steering gear motor may lead to a loss of the motor position sensor signal, resulting in a sudden loss of power assist while driving.The recall covers approximately 393,623 vehicles built from September 2010 through February 2012:2011-12 Fusion built SEP 2010 - FEB 2012; 2011-12 Lincoln MKZ built SEP 2010 - FEB 2012; 2011 Milan built SEP 2010 - DEC 2010; 2011-13 Taurus built SEP 2010 - FEB 2012; 2011-13 Flex with 3.5L GTDI engine built SEP 2010 - FEB 2012; and 2011-13 MKS, MKT with 3.5L GTDI engine built SEP 2010 - FEB 2012.The repair consists of updating the PSCM software to prevent a loss of steering assist while driving. The revised software will provide audible and visual warnings to the driver. If one or more of the following DTCs are stored, C1B00-62, C200B-2F, C200B-61, C200B-62, C200C-2F, C200D-49, U0300-00, U2011-49, U2011-61, U3000-46, U3000-49, U3000-61, U3000-72, U3000-96, P07AE-09, the dealer will replace the EPAS system at no charge to the owner.ODI's analysis of failure data for this PE identified a total of 2,584 complaints to ODI and Ford and 9,967 Ford warranty claims related to the alleged defect.The recalled vehicles account for 1,634 of the complaints and 7,311 of the warranty claims.ODI's analysis identified 40 complaints alleging crashes that may be related to loss of steering assist while driving, 20 of which involved vehicles included in Ford's recall.The information available for the alleged crashes were not sufficient to assess specific causes of the incidents or to verify EPAS malfunctions in each case.Most of the crashes were low-speed impacts with curbs or roadside objects resulting in wheel or minor body damage.None of the injury claims indicated medical attention was required.In addition, statistical modeling of the failure data by NHTSA's National Center for Statistics and Analysis projected 10-year failur

The contact owns a 2010 Ford Fusion. The contact stated that the ABS warning light was illuminated. The contact stated that an independent mechanic replaced the ABS sensors; however, the failure persisted. The contact stated that while driving at approximately 5-10 MPH, the brake pedal went to the floorboard while depressing the brake pedal, causing the stopping distance to be significantly extended. The vehicle was taken to the dealer, where it was diagnosed with ABS pump failure, which resulted in the rear calipers freezing. The contact associated the failure with NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic); however, the VIN was not included in the recall. The manufacturer was notified of the failure by phone. The failure mileage was approximately 175,000.

NHTSA ID

11773242

Incident

Sep 9, 2026

Mileage

175,000 mi

Electronic power steering

NHTSA ID

11768014

Incident

Sep 21, 2026

My brakes felt mushy for a couple days. Next day br a ke fluid dash light came on. brake fluid was so low couldn't see it. Went to autozone bought brake fluid .dot 3 per internet. Internet went on to share the fact thi s p r oblem was recalled. I h a v e none open says major safety problem tow xar immediately.im on s t at e assistance i can't pay to fix

NHTSA ID

11766161

Incident

Sep 21, 2026

We have had multiple issues with the ABS and HCU since we bought this car used a couple years ago. We've replaced the ABS Module and HCU and had Ford reprogram it and are still having issues. The brakes go out fully and I went through a red light. The ABS and Traction control and check brake system lights come on. We've spent a couple thousand dollars trying to fix this issue. The brakes have gone out before this incident as well around 95k miles and intermittently since. If needed, contact for invoices.

NHTSA ID

11765517

Incident

Sep 9, 2026

The contact owns a 2010 Ford Fusion. The contact stated that while driving approximately 65 MPH, the vehicle became difficult to maneuver and failed to return to normal operation. The advancetrac warning light was illuminated and the "Power Steering Fault" and "Advancetrac Failure" messages were displayed on the instrument panel. The manufacturer was notified of the failure. The failure mileage was approximately 130,000.

NHTSA ID

11764480

Incident

Aug 25, 2026

Mileage

130,000 mi

The contact owns a 2010 Ford Fusion. The contact stated that while driving 70 MPH, the vehicle experienced a loss of power steering assist. The traction control warning light was illuminated. The contact decelerated and pulled over to the side of the road. The vehicle was turned off and restarted. The vehicle resumed normal operation. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure. The failure mileage was approximately 120,000.

NHTSA ID

11753784

Incident

Jul 1, 2024

Mileage

120,000 mi

I was driving my car down the road and all the sudden I couldn't steer my car It caused me to go off the road and hit a ditch

NHTSA ID

11749370

Incident

Jul 9, 2026

Lug studs keep breaking off while driving

NHTSA ID

11749185

Incident

Jun 26, 2026

Ford and Lincoln vehicles equipped with wired keyless entry keypad systems and accessory wireless keyless entry keypad systems may or may not come with a wallet card containing the master code. Unlike the integrated wired keypad, the accessory wireless keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool or from the label printed on the body control module (BCM). The Factory Keyless Entry Code application within the diagnostic scan tool will not provide an applicable master code for the accessory wireless keypad. If the wallet card for an accessory keypad is not available, the "Wireless RF Keypad Diagnosis Guide" can be referenced and provides direction on how to retrieve the master code. This guide is located under the Workshop Manual tab > Accessories > Installation > Wireless RF Keypad Diagnosis Guide > PPT C > Step C2.<br /><br /> Note: The only available keypad for some vehicles from the assembly plant is the accessory wireless keyless entry keypad. The integrated wired keypad cannot be installed on vehicles not equipped from the factory with a wired keyless entry k

All accessory stick-on keyless entry keypads come with a wallet card containing the master code. If the accessory keypad was factory installed, this card will be placed in the glove box and should be handed to the vehicles owner during initial delivery. Unlike the integrated (wired) factory keypad, the accessory keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool. If the wallet card for an accessory keypad is lost, follow these steps to recover the code. Dealer Key Code access is granted through the Dealer Program Enrollment System (DPES); dealership management can authorize users. The authorized user must go to FMCDealer.com > Parts and Service > Parts Product Line Information > Keys/Entry Devices > Aftermarket Keyless Entry Keypad Code Access. Follow the instructions on the screen to obtain the master code for the accessory keypad.

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.

Certain 2005-2014 Mustang, 2005-2006 GT, 2004-2011 Ranger, 2006-2012 Fusion and MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge & MKX Vehicles Driver & Passenger Airbag Module Quality Control Inspection REASON FOR THIS SUPPLEMENT • Updated Ranger Technical Information to include images of a pass and fail airbag inflator inspection for 2007-2011 model years.

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.