2010 Ford Fusion Other / unspecified Problems

Lug studs keep breaking off while driving

NHTSA ID

11749185

Incident

Jun 26, 2026

We were made aware of Recall 11V574000 by our automotive shop, which applies to lugs/nuts/bolts on 2010 Ford Fusions, but only starting with manufacturer dates April 2009. This vehicle is dated February 2009, but we have replaced lugs/nuts/bolts at least 6 times in the past 5 years, clearly having the same problem. It has been an expensive, constantly reoccurring problem.

NHTSA ID

11734661

Incident

Apr 4, 2026

The contact owns a 2010 Ford Fusion. The contact stated that while the vehicle was parked, the wheel studs on the front passenger’s wheel detached from the wheel. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for further assistance. The failure mileage was approximately 61,000.

NHTSA ID

11680875

Incident

Aug 15, 2025

Mileage

61,000 mi

My steering wheel keeps locking up after I had the air bag recall taken care of

NHTSA ID

11638608

Incident

Jan 21, 2025

Multiple wheel studs have snapped in half, almost losing my wheel completely. This happened on all 4 wheels.

NHTSA ID

11594314

Incident

Jun 4, 2024

ALL OUT MOTORS IN CLIO MICHIGAN KNOWINGLY SELLS EXTREMELY DANGEROUS AND UNSAFE VEHICLES, TAKES ADVANTAGE OF YOUNG WOMAN WITH [XXX] SON AND TAKES EVERY DOLLAR OF HERS FOR A CAR THAT IS FAR FROM DRIVEABLE AFTER ONLY A C MONTH OR TWO AND HAS BEEN HIGHLY UNSAFE AND UNRELIABLE AND UNPREDICTABLE SINCE PURCHASE, DEALER REFUSED TO PROPERLY RESPOND TO SITUATION AND HARASSED THE MECHANIC WHO INSPECTED IT AFTER PURCHASE WHEN DEALER WAS CONFRONTED ABOUT SAFETY ISSUES. Every time there was any miniscule imperfection in the road, I would lose control of steering and the car would move into other lanes, unable to immediately correct it. Missing lug nut due to stud snapping off, when trying to replace it, all studs also broke off. All bolts in front caliper and caliper brackets also broke off, along with rear caliper snapping 3 days after vehicle purchase. Car is not drivable after having it 3 months. Multiple times while driving on highway the car would malfunction and lose power or steering wheel would lock up. These problems EASILY could've resulted in death and I have a [XXX] son who is always with me. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11592319

Incident

Mar 25, 2024

This vehicle has had multiple incidents in which the wheel studs on the front wheels will break off while driving. The last time this occurred, I noticed that 3 of the 5 wheel studs on the right-front wheel were broken off. When this was discovered, I contacted a Ford dealer and they said that there was no recall for this issue and didn't have any idea on how this had occured. I then contacted the last shop that had worked on the vehicle. They confirmed that the lug nuts were tightened using a torque wrench at the proper specifications. I have replaced several wheel studs and lug nuts on this vehicle in the past after they were found to be missing. The vehicle exhibits no vibration or warning signs while driving. This could have resulted in the wheel falling off while driving without warning.

NHTSA ID

11582664

Incident

Apr 12, 2024

Lug nuts are all stripped or broken. Check engine light, check fuel fill inlet message, poor driving all around, lack of power. Brake calipers broke off and brake pads fell out. Power steering locks up every once in a while

NHTSA ID

11581211

Incident

Mar 22, 2024

Took the Ford Fusion to the local Ford dealer to have the tires rotated. They said they could not remove the lug nuts as they have swelled. It is not possible to change a flat or rotate the tires.

NHTSA ID

11569771

Incident

Feb 4, 2024

I've had two issues with the power steering going out while driving, whic is very dangerous. The lug nuts also are fused on. I see recalls for these issues, although it says my vin# is not included. I hardly think I have the exact issues, but somehow they aren't related to these recalls. The date I am providing is the most recent. There was another over the summer

NHTSA ID

11558843

Incident

Nov 30, 2023

The contact owns a 2010 Ford Fusion. The contact stated that while starting the vehicle, the power steering assist fault and Service Advancetrac messages were displayed, and the traction control warning light was illuminated. The vehicle was towed to an independent mechanic, who diagnosed and determined that the power steering needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 120,000.

NHTSA ID

11557926

Incident

Oct 23, 2023

Mileage

120,000 mi

The contact owns a 2010 Ford Fusion. The contact stated that while starting the vehicle, the power steering default warning light would illuminate. In order to turn off the warning light, the contact had to turn off and then restart the vehicle. The failure occurred intermittently however, the failure persisted with the power steering assist default warning light remaining illuminated, with the service advancetrac and traction control warning lights illuminated. The contact took the vehicle to the dealer who diagnosed that there was an internal failure in the power steering module. The contact was informed that the steering gear needed to be replaced. The vehicle had not been repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 87,000.

NHTSA ID

11495453

Incident

Nov 30, 2020

Mileage

87,000 mi

Swollen or warped lug nuts.

NHTSA ID

11483665

Incident

Sep 9, 2021

ENGINE LIGHT, ADVANCE TRAC LIGHT, ABS LIGHT, BATTERY LIGHT, TIRE PRESSURE MONITORING SYSTEM LIGHT, ALARM LIGHT SUDDENLY CAME ON. THEN DASH WENT COMPLETELY BLANK. HEADLIGHTS WENT OUT,LOST CONTROL OF VEHICLE AT HIGH SPEED. DASH LIGHTS CAME BACK ON STIRRING CONTROL OF VEHICLE LOST. ALL DASH LIGHTS STARTED FLASHING. BREAKING SYSTEM NOT WORKING.

NHTSA ID

11396996

Incident

Feb 17, 2021

Mileage

82,500 mi

TL* THE CONTACT OWNS A 2010 FORD FUSION. THE CONTACT NOTICED WHILE WASHING THE VEHICLE THAT THE WHEEL STUDS WAS FRACTURED. THE CONTACT MENTIONED THAT THERE WAS NO VIBRATION WHILE DRIVING THE VEHICLE FROM THE WHEELS. THE VEHICLE WAS TAKEN TO A TIRE MECHANIC WHERE IT WAS DIAGNOSED THAT THE WHEEL STUDS NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED HOWEVER, THE FAILURE RECURRED MULTIPLE TIMES. THE VEHICLE WAS TAKEN TO EL CAJON FORD (1595 E MAIN ST, EL CAJON, CA 92021) WHERE THEY FAILED TO DO A DIAGNOSIS AND INFORMED THE CONTACT THAT THE RECALL WAS REPAIRED ON THE VEHICLE. THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER NHTSA CAMPAIGN NUMBER: 11V574000 (WHEELS). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THE CONTACT THE RECALL WAS REMEDIED WITH THE ONE-TIME FREE REPAIR. THE APPROXIMATE FAILURE MILEAGE WAS 103,000.

NHTSA ID

11387054

Incident

Feb 2, 2012

Mileage

103,000 mi

MY FUSION WAS ON RECALL FOR THE LUG NUTS. I TOOK MY CAR IN FOR THE REPLACEMENT LUG NUTS. THE NEW LUG NUTS ARE NOT THE SAME SIZE. I FOUND THAT OUT BY ROTATING MY TIRES. THE LUG RANCH FROM MY CAR DOES NOT FIT PROPERLY. THE COVERING OVER THE LUG NUTS THAT SUPPORTS THE HUB CAPS STRIPPED WHEN TRYING TO LOOSEN THE BOLTS. A STANDARD FOUR WAY LUG WRENCH WOULD NOT FIT ALSO. I WAS FORTUNATE MY NEIGHBOR WAS HOME WHO HAD A AIR GUN. HE HAD TO USE A DIFFERENT SIZE SOCKET TO EVEN GET THEM LOOSE. THE LUG NUT COVERS ON THE LUG NUTS ARE A DIFFERENT SIZE THEN THE OLD RECALL ONES. I NEVER HAD A PROBLEM BEFORE REMOVING THE OLD ONES WITH THE LUG RANCH THAT WAS PROVIDED WITH MY CAR. IF I HAVE A FLAT WHILE DRIVING THEIRS NO WAY OF CHANGING THE FLAT UNLESS YOU HAVE AN AIR GUN AND A CERTAIN SIZE SOCKET. I HAVE A FRIEND WHO DRIVES A FORD FUSION THAT HAD A TIRE THAT NEEDED TO BE CHANGED. THEY RAN INTO THE SAME PROBLEM WITH THE NEW LUG NUTS. THEY HAD TO CALL A TIRE STORE TO COME OUT TO THEIR HOME WITH AN AIR WRENCH AND A CERTAIN SIZE SOCKET TO REMOVE THE LUG NUTS. FORD MOTOR COMPANY NEEDS TO ADDRESS THIS PROBLEM. WHICH I DOUBT THEY WILL. THEY HAVEN'T REPLACE THE HCU YET ON MY CAR THAT I RECEIVED A RECALL ON A YEAR AGO. WHICH ENDING UP CAUSING ME TO WRECK THE CAR WHEN MY BRAKES FAILED AND CAUSING DAMAGES TO MY CAR.

NHTSA ID

11378641

Incident

Sep 14, 2020

WHILE DRIVING ON THE HIGHWAY THE LEFT DRIVER SIDE FRONT END OF THE FORD FUSION HIT THE RIGHT REAR/SIDE OF ANOTHER CAR ON THE HIGHWAY AFTER BEING CUT OFF BY ANOTHER CAR WEAVING IN & OUT OF TRAFFIC AT A HIGH SPEED. THE FORD FUSION WAS DESIGNATED "TOTALED" BY THE BODY SHOP AND INSURANCE ADJUSTER DUE TO THE EXTENSIVE DAMAGE. THE AIRBAGS NEVER DEPLOYED. THE AIRBAGS ON THIS FORD FUSION WERE PART OF THE AIRBAG RECALL AND WERE REPLACED BY THE FORD DEALERSHIP WITHIN THE LAST 2 YEARS SO THEY SHOULD HAVE BEEN IN GOOD WORKING ORDER BUT THEY NEVER DEPLOYED. VERY CONCERNING.

NHTSA ID

11364823

Incident

Oct 16, 2020

Mileage

115,000 mi

TL* THE CONTACT OWNS A 2010 FORD FUSION. THE CONTACT STATED THAT AFTER SHE PARKED THE VEHICLE, SHE BECAME AWARE THAT THE FRONT DRIVER'S SIDE WHEEL WAS MISSING A WHEEL STUD AND LUG NUT. THE CONTACT STATED THAT THE FAILURE WAS EXPERIENCED ON THE DRIVER'S AND PASSENGER'S SIDE FRONT WHEELS A TOTAL OF 8 TIMES. THE VEHICLE WAS TAKEN 8 TIMES TO LAIRD NOLLER FORD TOPEKA LOCATED AT 2245 SW TOPEKA BLVD, TOPEKA, KS 66611, (785) 235-9211 AND THE WHEEL STUD AND A LUG NUT WERE REPLACED. THE MANUFACTURER HAD NOT BEEN INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 35,998.

NHTSA ID

11364649

Incident

Jan 1, 2012

Mileage

35,998 mi

OUR CAR HAS EXPERIENCED THREE BROKEN WHEEL STUDS TO DATE. A RECALL HAS BEEN ISSUED FOR THIS SAFETY DEFECT FOR THIS MODEL AND YEAR OF VEHICLE. THE DEALER AND THE MANUFACTURER STATE OUR CAR IS NOT COVERED FOR THIS MANUFACTURING DEFECT BECAUSE OF THE VIN NUMBER. WE HAVE PAID THE DEALER FOR THESE REPAIRS. BUT THE SAFETY DEFECT IS NOT A DEFECT BECAUSE OF THE VIN NUMBER? THE BROKEN WHEEL STUDS ARE AWARE OF THE VIN NUMBER?

NHTSA ID

11340832

Incident

Jul 21, 2020

Mileage

110,000 mi

TL* THE CONTACT OWNS A 2010 FORD FUSION. THE CONTACT STATED THAT THE LUG NUTS WERE DIFFICULT TO REMOVE FROM THE VEHICLE WHILE ATTEMPTING TO CHANGE TIRES ON THE VEHICLE. THE CONTACT STATED THAT THE FAILURE WAS DUE TO THE TWO-PIECE LUG NUT FUSING TOGETHER. ADDITIONALLY, WHILE DRIVING, THE OUTER SHELL OF THE LUG NUTS DETACHED. THE CONTACT STATED THAT THE BRAKING DISTANCE WAS ALSO EXTENDED WHILE DEPRESSING THE BRAKE PEDAL. INDEPENDENCE FORD LOCATED AT 3101 COLUMBIA BLVD, BLOOMSBURG PA, 17815 AND MANUFACTURER WERE NOTIFIED OF THE FAILURE HOWEVER, NO ASSISTANCE WAS OFFERED. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE FAILURE MILEAGE WAS 115,000. *BF*JB

NHTSA ID

11325942

Incident

Nov 1, 2019

Mileage

115,000 mi

DASH PANEL INDICATED DOOR AJAR, EMERGENCY AND OTHER BRAKES WERE ENGAGED, TIRE PRESSURE LOW, INTERIOR LIGHTS CAME ON, BLINKERS NO LONGER WORK. THIS ALL HAPPENED SUDDENLY WHILE DRIVING DOWN A FLAT STREET, 25 MPH, WEATHER WAS 65 DEGREES, DRY WEATHER, DURING THE DAY. *TR

NHTSA ID

11325656

Incident

May 23, 2020

TL* THE CONTACT OWNS A 2010 FORD FUSION. THE CONTACT STATED THAT UPON PURCHASING THE VEHICLE FROM ROUSH FORD 5575 KEIM CIR, COLUMBUS, OH 43228, SEVERAL LUG BOLTS USED TO SECURE THE FRONT WHEELS ON THE DRIVER AND PASSENGER OF THE VEHICLE FRACTURED WITHOUT WARNING. THE VEHICLE WAS TAKEN BACK TO THE SAME DEALER AND WAS REPAIRED HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS ALSO TAKEN TO SEVERAL INDEPENDENT MECHANIC FOR SIMILAR FAILURES. THE MANUFACTURER HAD BEEN NOTIFIED OF THE FAILURE AND OFFERED NO ASSISTANCE. THE VEHICLE NOT REPAIRED. THE FAILURE MILEAGE WAS 18,900. *LN

NHTSA ID

11307491

Incident

Jul 17, 2012

Mileage

18,900 mi

ONE MORNING WHEN MY WIFE WAS GETTING READY TO LEAVE FOR THE GYM HER CAR SAID 'POWER STEERING ASSIST FAULT.' NOW THE CAR HAS NO POWER STEERING AND IF YOU TRY TO DRIVE IT IT FLASHES 'SERVICE ADVANCE TRAC NOW. SADLY WE DON'T HAVE THE MONEY TO FIX THIS SO THE CAR IS STUCK IN THE DRIVE WAY.

NHTSA ID

11297453

Incident

Sep 2, 2019

Mileage

143,000 mi

TL* THE CONTACT OWNS A 2010 FORD FUSION. THE CONTACT STATED THAT THE ELECTRONIC STEERING WHEEL SEIZED IN THE PARK POSITION. THE VEHICLE WAS TOWED TO ALL AMERICAN FORD OF OLD BRIDGE (3698 U.S. 9, OLD BRIDGE, NJ 08857, (732) 242-0404); HOWEVER, AFTER FOUR DAYS, THE VEHICLE HAD NOT BEEN DIAGNOSED OR REPAIRED. THE VEHICLE WAS SUBSEQUENTLY TOWED FROM THE DEALER TO AN INDEPENDENT MECHANIC TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE ELECTRONIC STEERING SYSTEM NEEDED TO BE REPLACED. THE CONTACT WAS PROVIDED AN ESTIMATE OF $1,400 FOR THE REPLACEMENT PART. THE CONTACT WAS ALSO INFORMED THAT THE TIE RODS NEEDED TO BE REPLACED AND AN ALIGNMENT WAS NEEDED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED AND PROVIDED A CASE NUMBER. THE FAILURE MILEAGE WAS 119,000.

NHTSA ID

11297452

Incident

Jul 1, 2019

Mileage

119,000 mi

TL* THE CONTACT OWNS A 2010 FORD FUSION. WHILE THE VEHICLE WAS UNDERGOING A ROUTINE INSPECTION AT SUNNYVALE FORD (650 E EL CAMINO REAL, SUNNYVALE, CA 94087, (408) 215-9949), THE MECHANIC NOTICED THAT THE FRONT DRIVER'S SIDE WHEEL LUG NUT WAS FRACTURED AND THE WHEEL COULD NOT BE REMOVED. THE VEHICLE WAS REPAIRED. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 11V574000 (WHEELS). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND PROVIDED CASE NUMBER: 25152622. THE FAILURE MILEAGE WAS 118,000.

NHTSA ID

11288864

Incident

Nov 28, 2019

Mileage

118,000 mi