RoadVitals

2012 Ford Fusion Body & structure Problems

Owner-reported complaints naming the body or structure system, filed with NHTSA

Data refreshed

Body & structure reportsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
95
Latest Apr 24, 2025
Share of all reportsThis category as a share of every owner report on file for this model year. One report can name more than one component, so the categories overlap.
4%
of 2,511 total
Crash or fire reportedReports in this category whose submitter recorded that a crash or a fire occurred. The reporter's own answer on the NHTSA form, not a verified finding.
13
Injuries or deaths reportedTotals the submitters entered on their own reports in this category. Not verified by NHTSA and not a casualty statistic.
8

What this page shows

Reports naming the vehicle structure, frame, body panels, doors, hood and trim. Every record below is an owner-reported complaint about the 2012 Ford Fusion submitted to NHTSA — not a confirmed defect, not a recall and not a manufacturer bulletin. 95 reports on file name it.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

Owner reports naming body or structure

The 25 most recent of 95, in the owner's own words

Body & structureFuel systemSuspension
Filed Apr 24, 2025

Absolute unacceptable level of rust to the body and frame. Even with regular car washes, sitting for a year covered. It’s literally totalled and I am out of a car. It’s a 2012 with this amount of rust

NHTSA ID
11656538
Incident
Apr 24, 2025
Body & structure
Filed Nov 23, 2024

Driver door is not locking. Tried with manual key too but not successful. Tried to open door from inside but no success. Looks like door assembly or spring is faulty and designed poorly This can be a safety hazard as driver can't get out of car easily. Pls recall all Ford fusion 2012 and ask dealers to fix it. I checked few articles forums and YouTube videos and everywhere it says there might be a spring problem or some plastic issue in latch or door assembly.

NHTSA ID
11627056
Incident
Nov 23, 2024
Body & structure
Filed Jun 6, 2024

Door latch keeps falling have to roll down the window to open the door from the outside

NHTSA ID
11592889
Incident
Jun 8, 2021
Body & structure
Filed Apr 5, 2023

This is the second time my door latch has malfunction. I'm a single parent and to keep having to come out of pocket to get the same issue fixed is a big inconvenience.The inside is broken I have to roll my window down and unlock my door from the outside just to get out of my car. This is a major safety hazard why hasn't the recalled 2012 Ford fusions been included for the door latches? I can't even lock my door and there has been numerous break-ins close by.

NHTSA ID
11515653
Incident
Mar 22, 2023
Body & structure
Filed Mar 6, 2023

Driver inside door handle does not allow the door to be opened.

NHTSA ID
11510286
Incident
Mar 5, 2023
Body & structure
Filed Dec 19, 2022

Front Driver Side door handle mechanism breaks and will not open the door when the lock mechanism is in the Unlocked position. To open the door from the interior, the driver must roll down the electrically-powered window and use the exterior latch to open the door. There are multiple examples of these situations and the owner’s description of repairs. Here is one example: https://youtu.be/At96DIaPyc8 This is a serious and significant safety hazard for the vehicle driver, particularly in the event of a vehicle fire or water submersion.

NHTSA ID
11498075
Incident
Nov 1, 2022
Body & structure
Filed Nov 26, 2021

Door handle open mechanism failed (of driver side door) thus causing a safety issue because you cannot exit the vehicle when inside, except by rolling down the window. This issue has been reported by several other owners.

NHTSA ID
11441785
Incident
Oct 1, 2021
Body & structure
Filed Jul 3, 2021

Over the past few days driver side door would not open from the inside of the vehicle. Rolling down the window and opening the door from the outside is the only option in opening the driver side car door. This is a safety concern as if I were ever in need to exit the vehicle in an emergency manner I can not easily or quickly get out of the car we’re under water, on fire, etc. My vehicle is not the only vehicle that is having this issue, I have heard reports from mechanics, other Ford Fusion Drivers, and personal experience that Ford Fusions from about 2006-2013 are having this issue. The issue needs to be addressed for safety concerns and is only happening on the drivers side door.

NHTSA ID
11423304
Incident
Jun 24, 2021
Body & structure
Filed Apr 11, 2021

THE DRIVER DOOR OPENED WHILE I WAS DRIVING AND I AM CERTAIN THAT I CLOSED IT BEFORE DRIVING. THEN, THE INNER HANDLE PREVENTED MY DOOR FROM BEING OPENED FROM THE INSIDE CAUSING ME TO HAVE TO ROLL DOWN THE WINDOW TO OPEN THE DOOR. A WEEK LATER, TODAY, AND THE LOCK HANDLE HAS NOW FALLEN OFF. NOTICE PHOTOS OF BROKEN LOCK THAT FELL OFF, ALSO, THE DOOR HANDLE HAS ZERO TENSION WITH ONLY A FINGER CAUSING THE DOOR HANDLE TO BE INOPERABLE.

NHTSA ID
11407522
Incident
Apr 11, 2021
Mileage
20,000 mi
Body & structure
Filed Oct 26, 2020

WHEN I WAS PREPARING TO EXIT MY VEHICLE AT A CONSTRUCTION ROADWAY (I WAS LOST) MY DRIVERS' DOOR HANDLE WOULD NOT OPEN- IT FLOPPED. I COULD NOT EXIT. I CALLED MY FAMILY FOR HELP TO FIND OUT WHAT TO DO. (I AM A SENIOR AND COULD NOT CLIMB OVER THE STICK TO USE THE OTHER DOOR) MY FAMILY SAID TO LOWER THE WINDOW AND OPEN THE DOOR FROM THE OUTSIDE AND "BE CAREFULL!" AFTER THAT I WENT HOME AND WHEN I TRIED TO CLOSE THE DOOR- IT WOULD NOT LATCH/NOR CLOSE- ONCE AGAIN I CALLED FOR HELP AND WAS TOLD TO TIE THE DOOR CLOSE THRU THE WINDOWS. WHICH MEANT MY DOOR WAS VUNABLE TO THEFT AND WEATHER. WHEN I SPOKE WITH THE FORD DEALER SERVICE DEPARTMENT, I WAS TOLD THAT THIS IS "A COMMON PROBLEM WITH OLDER MODELS"(MINE IS A 2012!).PER THE DEALER IT REQUIRES A DOOR LOCK PART. WHAT IT TELLS ME IS THE SAFETY FEATURES ON "OLDER MODELS" EXPIRE WITH THE WARRANTIES! BUT THIS IS WHY I PURCHASED A FORD!! HAD I KNOW THE "SAFETY FEATURES" EXPIRE WITH THE WARRANTY, I WOULD HAVE RESEARCHED WHICH VEHICLE HAS THE BEST & LONGEST "SAFETY FEATURES"! I NOW FEEL UNSAFE DRIVING THIS VEHICLE DUE TO MY INABILITIES TO EXIT IN CASE OF AN EMERGENCY DUE TO FAULTY/EXPIRED "SAFETY FEATURES!" IT MAKES ME FEEL I WOULD BE TRAPPED WITHOUT A WAY OUT! IF THIS IS COMMON-WHY ISN'T IT STATED SOMEWHERE FOR SENIORS TO KNOW IN ADVANCE- ESPECIALLY BEFORE PURCHASING A FORD WITH COMMON SAFETY DEFECTS!? HOW MANY SENIORS/OWNERS HAVE TO BECOME INJURED OR DIE BEFORE FORD REPORTS THIS AS A FAILED SAFETY FEATURE??!! AIRBAGS, SEATBELTS, ... - DOOR LOCKS ON DRIVER'S DOOR SHOULD BE ADDED TO THE RECALL LIST BEFORE IT RESULTS IN MANY INJURIES/DEALTHS! IT IS A CHEAP PART TO REPLACE PER FORD DEALER AND COULD BE REASON WHY IT IS NOT A RECALL BUT AT LEAST IT SHOULD A NOTICE SENT TO OWNERS SO THEY CAN AVOID IT HAPPENING TO THEM.LUCKLY MY INCIDENT OCCURRED IN DAYTIME- THIS COULD HAVE BEEN WORSE AT NIGHT!?

NHTSA ID
11366374
Incident
Oct 24, 2020
Mileage
66,000 mi
Body & structure
Filed Jun 23, 2020

TL* THE CONTACT OWNS A 2012 FORD FUSION. THE CONTACT STATED THAT THE DRIVER'S SIDE FRONT DOOR FAILED TO OPEN FROM INSIDE OF THE VEHICLE. THE CONTACT CALLED MIKE BASS FORD INC (5050 DETROIT RD, SHEFFIELD, OH 44035, (440) 934-3673), AND THE DEALER WAS INFORMED OF THE FAILURE. THE CONTACT WAS INFORMED TO SCHEDULE AN APPOINTMENT TO HAVE THE VEHICLE DIAGNOSED. THE CONTACT STATED THAT THE FAILURE OCCURRED BEFORE AND WAS TAKEN TO THE SAME DEALER, WHERE THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT THE VEHICLE WAS OUT OF WARRANTY. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 56,000.

NHTSA ID
11330347
Incident
Jul 4, 2018
Mileage
56,000 mi
Body & structure
Filed Jun 13, 2020

MY PASSENGER FRONT SIDE DOOR LOCK WILL NOT (UNLOCK OR LOCK) WHILE THE CAR IS IN MOTION OR STATIONARY. IT IS STUCK IN THE LOCKED POSITION WHEN I USE MY KEY PAD AND TRYING TO USE THE UNLOCK BUTTON IN MY CAR. I'M ALSO HAVING DIFFICULTIES WITH THE MY DRIVER SIDE DOOR LATCH WHILE STATIONARY. WHEN I'M READY TO EXIT MY CAR AFTER DRIVING, I URN OFF MY IGNITION; OPEN MY DRIVER SIDE DOOR; AND SHUT THE DOOR BUT SOMETIMES THE DOOR LATCH GET JAMMED AND NOT WANT TO CLOSE (THE LATCH WOULD BE FACING DOWN). *TR

NHTSA ID
11328621
Incident
Apr 13, 2020
Mileage
136,500 mi
Body & structureInterior & seats
Filed May 7, 2020

TL* THE CONTACT OWNS A 2012 FORD FUSION. THE CONTACT STATED THAT THE PASSENGER'S SIDE FRONT DOOR HANDLE FAILED TO UNLOCK THE VEHICLE FROM OUTSIDE OF THE VEHICLE. THE CONTACT STATED THAT OVER TIME, THE DRIVER'S SIDE AND PASSENGER'S SIDE REAR OUTER DOOR HANDLES ALSO EXPERIENCED SIMILAR FAILURES. THE VEHICLE WAS FIRST TAKEN TO CHINO HILLS FORD (4480 CHINO HILLS PKWY, CHINO, CA 91710) TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THERE WAS A DIAGNOSTIC FEE TO HAVE THE VEHICLE DIAGNOSED. THE CONTACT DECLINED TO PAY TO HAVE THE VEHICLE DIAGNOSED. THE FAILURE WORSENED AND FORD OF UPLAND (555 W FOOTHILL BLVD, UPLAND, CA 91786) WAS CONTACTED AND INFORMED OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE VEHICLE NEEDED TO BE DIAGNOSED AND A COST WOULD BE ASSESSED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 90,000.

NHTSA ID
11323643
Incident
May 1, 2018
Mileage
90,000 mi
Body & structure
Filed Mar 25, 2020

DRIVER SIDE INSIDE DOOR OPENING HANDLE BROKE TWICE. I FIXED IT WITH A USED PART FROM THE EXACT SAME YEAR AND MODEL OF CAR WITH SIMILAR MILEAGE, BUT IT BROKE AGAIN IN 3 MONTHS TIME. IT'S NOT JUST A PAIN IN THE BUTT TO GET OUT, IT'S ALSO A SAFETY ISSUE. IF A PERSON WAS IN A WRECK AND CAN'T OPEN THE ELECTRIC WINDOW HOW WOULD I EXIT THE VEHICLE IN A HURRY? THIS HAPPENED AS I WAS ATTEMPTING TO EXIT THE CAR AFTER ARRIVING AT WORK. THERE IS A SMALL THIN PLASTIC PIECE THAT BREAKS OFF OF THE HANDLE YOU PULL TO OPEN THE DOOR, ONCE IT BEAKS THE ONLY WAY TO GET THE DOOR OPEN IS TO LOWER THE DRIVERS WINDOW, REACH OUTSIDE TO GET AHOLD OF THE OUTER DOOR HANDLE TO OPEN IT FROM THERE. IF YOU CAN'T DO THAT YOU MUST CRAWL OVER THE PASSENGER SEAT TO EXIT UNLESS SOMEONE CAN OPEN THE DOOR FOR YOU.

NHTSA ID
11319261
Incident
Dec 18, 2019
Mileage
92,000 mi
Body & structure
Filed Feb 26, 2020

DRIVER'S DOOR LATCH STOPPED WORKING. SUDDENLY COULD NOT OPEN THE DOOR TO EXIT VEHICLE AFTER PARKING IT. DOOR DOES OPEN FROM THE OUTSIDE BUT NOT FROM WITHIN.

NHTSA ID
11311722
Incident
Feb 2, 2020
Mileage
57,000 mi
Body & structure
Filed Jan 31, 2020

DOOR ON DRIVERS SIDE LOCK JAMS. DRIVER HAS TO OPEN DOOR FROM OUTSIDE. ARE THERE ANY RECALLS FOR THIS CAR DOOR LOCKS?

NHTSA ID
11306221
Incident
Jan 27, 2020
Body & structure
Filed Jan 7, 2020

TL* THE CONTACT OWNS A 2012 FORD FUSION. THE CONTACT STATED THAT THE FRONT DRIVER'S SIDE DOOR HANDLE FRACTURED. THE CONTACT STATED THAT THE DOOR HANDLE FRACTURED AND WAS REPLACED TWICE PREVIOUSLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE CONTACT STATED THAT THE VEHICLE WAS SCHEDULED TO BE INSPECTED BY AN INDEPENDENT MECHANIC. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS INFORMED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 93,000.

NHTSA ID
11297563
Incident
Nov 2, 2016
Mileage
93,000 mi
Body & structure
Filed Aug 11, 2019

BOTH PASSENGER & DRIVER SIDE DOOR HANDLES BROKE. COULD NOT OPEN CAR DOORS FROM THE INSIDE. HAD TO OPEN WINDOW TO OPEN DOORS FROM THE OUTSIDE. DEALER SAID THIS WAS NOT COVERED UNDER WARRANTY AND PAID TO HAVE BOTH ASSEMBLY'S REPLACED. THIS IS A MAJOR SAFETY ISSUE AS I WOULD NOT HAVE BEEN ABLE TO GET OUT OF MY CAR RIGHT AWAY IN CASE OF EMERGENCY.

NHTSA ID
11243061
Incident
May 1, 2017
Body & structure
Filed Jul 24, 2019

DRIVER SIDE DOOR LATCH WILL NOT LATCH AND STAY SHUT. THERE WAS A RECALL FOR DOOR LATCHES IN 2013-2014 (RECALL 15516) BUT MY 2012 VIN IS NOT INCLUDED IN ANY RECALL. THIS JUST OCCURED YESTERDAY AND NOW LATCH WILL NOT KEEP DOOR SHUT. CAR STATIONARY. UNABLE TO SAFELY DRIVE MY CAR BECAUSE DOOR WILL NOT STAY CLOSED.

NHTSA ID
11234556
Incident
Jul 23, 2019
Mileage
102,362 mi
Body & structure
Filed Jul 11, 2019

SQUEAKS AND CREAKS HEARD WHILE DRIVING OVER BUMPS AND TURNING CAN BE CAUSED BE A COUPLE COMMON SOURCES AND SHOULD BE CAREFULLY DIAGNOSED. POSSIBLE WELD ISSUES ON THE LOWER CONTROL ARMS CAN CAUSE THE NOISE CONCERN

NHTSA ID
11231009
Incident
Jul 1, 2019
Mileage
80,000 mi
Body & structureElectrical
Filed Mar 29, 2019

DRIVER SIDE DOOR WILL NOT OPEN FROM THE INSIDE. WHEN INSIDE THE VEHICLE THE DOOR HANDLE FEELS LOOSE AND MOVES FREELY WHEN PULLING BUT THE DOOR WILL NOT OPEN. YOU CAN OPEN THE DOOR FROM THE OUTSIDE.

NHTSA ID
11192360
Incident
Mar 29, 2019
Mileage
57,882 mi
Body & structure
Filed Feb 21, 2019

DRIVERS SIDE DOOR HANDLE DOESN'T WORK. DOOR CAN NOT BE LOCKED. THERE IS A SAFETY RECALL ON THE 2013/2014 FUSION FOR A SIMILAR ISSUE.

NHTSA ID
11181532
Incident
Nov 17, 2018
Mileage
102,000 mi
Body & structure
Filed Feb 13, 2019

I WAS PARKED. I WAS SITTING IN THE DRIVER'S SEAT TRYING TO GET OUT OF THE DRIVER'S SIDE DOOR. I PULLED ON HANDLE AND SOMETHING INSIDE THE DOOR BROKE. I COULD PULL THE HANDLE BUT THE DOOR WOULD NOT OPEN. I COULD NOT OPEN THE WINDOW BECAUSE THE WINDOW WAS FROZEN SHUT. IT WAS QUITE TERRIFYING THINKING I WOULD BE STUCK IN THE COLD. THEN I REALIZED I COULD EXIT THROUGH ANOTHER DOOR BUT I HAD TO CRAWL INTO THE PASSENGER SEAT FROM THE DRIVER'S SEAT. IF THIS HAD BEEN AN EMERGENCY SITUATION, I DON'T THINK IT WOULD BE SAFE FOR THE DOOR TO LOCK SHUT LIKE THAT. SINCE THEN, I HAVE NOT BEEN ABLE TO OPEN THE DRIVER'S SIDE DOOR FROM THE INSIDE, AND IF I CAN'T OPEN THE WINDOW IN FREEZING WEATHER TO REACH OUTSIDE (FROM INSIDE) THE CAR TO OPEN IT, I HAVE TO CRAWL TO PASSENGER'S SEAT TO GET OUT.

NHTSA ID
11179965
Incident
Jan 16, 2019
Mileage
70,000 mi
Body & structure
Filed Jan 17, 2019

THE DRIVERS SIDE DOOR WILL NOT OPEN FROM INSIDE AT ALL. I HAVE TO HAVE SOMEONE OPEN IT FROM THE OUTSIDE FOR ME OR ROLL DOWN THE WINDOW TWIST AROUND IN THE SEAT AND OPEN IT FOR MYSELF. I THEN HAVE TO ROLL THE WI DOW BACK UP. I HAVE ONLY 72120 MILES ON THIS CAR. IT IS RIDICULOUS. I CAN EASILY GET TRAPPED INSIDE IN AN ACCIDENT AND NOT BE ABLE TO GET MYSELF OUT. I CALLED THE DEALERSHIP AND WAS TOLD THAT IT WAS NOT UNDER WARRANTY AND I WOULD NEED TO FIX IT AT COST. I AM THE ONLY OWNER OF THIS CAR HOW IS THAT POSSIBLE? I LOOKED ONLINE TO SEE HOW MANY OTHERS HAVE HAD THIS ISSUE AND IT IS A SERIOUS PROBLEM. HOW HAS NOBODY GOTTEN KILLED BY BEING TRAPPED IN THE CAR? LUCK! I AM SCARED TO DRIVE IT SINCE IT IS WINTER AND KNOW MY FELLOW DRIVERS ARE NOT AS CAUTIOUS AS I AM. I NEED TO SAVE UP MONEY TO BE ABLE TO GET THIS FIXED YET I AM SCARED TO DRIVE TO WORK. WHAT A CRAZY WORLD WE LIVE IN. U WILL NEVER BUY FORD AGAIN AND IT WAS BRAND NEW.

NHTSA ID
11170538
Incident
Jan 2, 2019
Mileage
72,120 mi
AirbagsBody & structure
Filed Nov 27, 2018
Crash reported1 injury reported

TAKATA AIRBAGS DID NOT DEFLATE IN CAR ACCIDENT FOR SAFETY PURPOSE.

NHTSA ID
11154306
Incident
Jun 1, 2017
Mileage
60,000 mi

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.

Other components reported on this vehicle

Categories with enough reports to have a page of their own

Elsewhere on this vehicle

Data sources

Data on this page last refreshed .