2015 Ford Fusion Fuel system Problems

I own a 2015 Ford Fusion SE. I bought it used when it only had 47,000 miles on it. Over the course of time since buying it in DEC 2022 until now, it has had low coolant that I have had to address but no visible leaks. Current mileage now is 87,100 and just recently the coolant was low again and the check engine light came on for DTC P0301 -Cylinder 1 misfiring. It has had rough start ups, rough idle, decreased acceleration, and poor fuel efficiency. I have found the problem to be Coolant Intrusion – Engine Defect Concern “Coolant intrusion” is a known engine design defect in which coolant leaks into the cylinders, leading to internal damage, misfires, and eventual engine failure. After researching it I found that many other people have had the very same issue with no help from Ford. This should be a recall as this is an internal issue with the short block and something that should have been disclosed before purchasing this model/engine. The only repair that will fix the core of the issue is replacing the entire short block which costs thousands of dollars, way more than the cost of the entire vehicle at this point. Without fixing the issue, the engine will fail. Again, this should be something Ford should pay to repair, not any customer who came into this blind.

NHTSA ID

11735885

Incident

May 4, 2026

I am reporting a serious and ongoing safety issue involving my 2015 Ford Fusion. The vehicle experiences intermittent power steering failure while driving. The steering assist will suddenly disengage and re-engage without warning, making the vehicle extremely difficult to control. This condition becomes even more dangerous in wet weather, where the vehicle is sometimes nearly undriveable. Additionally, I am now experiencing a popping noise in the steering wheel. This raises concern of a possible mechanical failure consistent with known recalls involving steering wheel bolt defects that could result in the steering wheel detaching. These issues are consistent with known recalls, including: - Power Steering Failure Recall (15V340000) - Steering Wheel Bolt Recall (18V167000 / 18S08) Despite these known safety defects, Ford has refused to repair the issue, stating that the recall has expired. This presents a serious safety hazard, including risk of loss of steering control, crash, injury, or death. I am requesting immediate investigation and enforcement of manufacturer responsibility for this safety-related defect.

NHTSA ID

11735316

Incident

Apr 10, 2026

The contact owns a 2015 Ford Fusion. The contact stated that the vehicle was serviced under NHTSA Campaign Number: 23V162000 (Service Brakes, Hydraulic) and Ford Customer Satisfaction Program: 20R01, 22R01, and 25E01. The contact stated that after the vehicle was serviced, the vehicle was dropped off at the contact's residence. The contact stated that upon starting the vehicle, the check engine warning light was illuminated. The contact called the dealer, and the dealer picked up the vehicle. The contact was informed that the vehicle displayed a fuel pressure and ambient air temperature sensor issue. The vehicle was not repaired due to the cost. The vehicle was at the residence. The contact parked and stopped driving the vehicle due to the safety concern. The manufacturer was notified of the failure. The failure mileage was approximately 111,383.

NHTSA ID

11701727

Incident

Nov 26, 2025

Mileage

111,383 mi

Over the course of 3 weeks I started to notice a strong smell of gasoline after filling my fuel tank that lasted for about the first quarter of the tank. I did look around the car and under it to see if I could observe a leak, but saw nothing upon visual inspection. After about 3 weeks I observed a very strong smell of gasoline when I walked out to the car in the morning and observed gasoline on the rim of the passenger side tire as well as on the ground by the tire. At that point I looked up recalls on the 2015 fusion and did find one on the fuel system but was advised that it is not active on my vin. I took my car to a local shop where they found that both fuel senders were wet and leaking thus causing the fuel leak.

NHTSA ID

11646905

Incident

Jan 28, 2025

The contact owns a 2015 Ford Fusion. The contact stated that while attempting to start the vehicle, the vehicle failed to start. After several attempts to start the vehicle, the vehicle started. The contact stated while driving 40 MPH, the vehicle lost automotive power and stalled. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic to be diagnosed and was diagnosed with canister purge valve failure. The vehicle was repaired; however, the check engine warning light became illuminated. The failure recurred two more times. The local dealer was not contacted. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline. The failure mileage was approximately 80,000.

NHTSA ID

11635690

Incident

Aug 24, 2019

Mileage

80,000 mi

The contact owns a 2015 Ford Fusion. The contact stated while driving at various speeds, the vehicle lost motive power and stalled. There was no warning light illuminated. The contact made several attempts to restart the vehicle before being able to continue driving. The failure at first was intermittent but became more persistent. The vehicle was taken to a certified mechanic who diagnosed that the EVAP system had failed. The vehicle was not repaired. The manufacturer was made aware of the failure. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was 160,000.

NHTSA ID

11623398

Incident

May 4, 2024

Mileage

160,000 mi

My vehicle will not turn on after refueling, but there are no signs of visible damage. The check engine light remains illuminated, and the code read for the O2 sensors. The RPM jump up and down at the slightest push of the accelerator, and occasionally the engine will shut off when RPM drops to idle speed.

NHTSA ID

11613877

Incident

Nov 16, 2023

After fueling in the car up i drive it and it stalls out while driving

NHTSA ID

11591122

Incident

May 28, 2024

The contact owns a 2015 Ford Fusion. The contact stated that after refueling the vehicle, the vehicle would fail to start up after multiple attempts without warning. The contact stated that the vehicle eventually restarted and operated normally. The contact stated that the vehicle hesitated upon depression of the accelerator pedal without warning. The vehicle was taken to a dealer however, the mechanic was unable to determine the cause of the failure. The manufacturer was also notified of the failure and was referred to the NHTSA Hotline for assistance. The vehicle was not repaired. The failure mileage was approximately 73,000.

NHTSA ID

11564684

Incident

Dec 21, 2023

Mileage

73,000 mi

The contact owns a 2015 Ford Fusion. The contact stated that while driving on a highway at unknown speeds, the vehicle lost motive power and stalled. The contact activated the hazard lights and veered to the side of the road. While the contact’s wife was reversing, the vehicle began to drive roughly and stalled. Upon accelerating from a stop light, the vehicle stalled. The check engine warning light was illuminated. The contact's son inspected the vehicle and received codes for low fuel pressure. The vehicle was taken to an independent mechanic, who informed him that there was low fuel pressure and that the fuel pump and fuel sensor needed to be replaced. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The vehicle was not repaired. The manufacturer was contacted and opened a case and referred the contact to the NHTSA Hotline. The failure mileage was approximately 39,000.

NHTSA ID

11563781

Incident

Jun 1, 2023

Mileage

39,000 mi

Previously, about 5-6 times the car experienced sputtering and then stalling shortly after a warm engine restart. After 2 tries, the car would continue running. No check engine. No codes stored. Final time (before a scheduled shop visit) it stalled on a busy 4-lane road at rush hour and would not restart. Wife managed to manuever into the middle turn lane. Would not restart. Car displayed (unhelpfully) to check the owners manual. Towed to Firestone who found bad spark plugs (in particular cylinder 3) showing coolant leakage. Firestone seemed to be aware of the systemic issues (said replacing plugs was not solving the root problem, but they don't do engine replacements. Estimated that the car might run correctly for maybe a year. Car stalled again 3 days later). Coolant level was low. My experience seems similar to many others (ie., 2013-19 engine coolant leak). Car at dealership.

NHTSA ID

11563334

Incident

Dec 15, 2023

The contact owns a 2015 Ford Fusion. The contact stated that his daughter was unable to start the vehicle. The contact stated no warning light was illuminated. The contact took the vehicle to the local dealer, where it was diagnosed with needing the purge valve to be replaced. The vehicle was repaired but experienced the failure a second time in 2022. The contact took the vehicle back to the local dealer, where it was diagnosed with needing the purge valve to be replaced a second time. The vehicle was repaired but experienced the failure a third time on July 26, 2023. The contact took the vehicle back to the local dealer, where it was diagnosed with needing the purge valve to be replaced a third time. The vehicle was not repaired. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 18V735000 (Fuel System, Gasoline) however, the VIN was not included. The manufacturer had been informed of the failure. The failure mileage was unknown.

NHTSA ID

11535098

Incident

Jan 1, 2021

Mileage

141,299 mi

In July 2021 I had the CPV replaced because the purge valve was stuck open. Now, less than 2 years later, 45,000 miles later, I am once again having the same issue. Code P1450. Unable to bleed up fuel tank. Just like last time. My vehicle check engine light is on and after I get gas my car starts sputters and does not want to start.

NHTSA ID

11511799

Incident

Mar 11, 2023

The contact owns a 2015 Ford Fusion. The contact stated while driving at various speeds, the vehicle suddenly shuddered, hesitated, decelerated and stalled. The contact stated upon restarting the vehicle, the vehicle would operate as needed. The vehicle was taken to the dealer who was unable to duplicate the failure. However, the failure reoccurred increasingly while driving. The vehicle was taken back to the dealer who diagnosed that the throttle body had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 63,785.

NHTSA ID

11479039

Incident

May 24, 2019

Mileage

63,785 mi

I am not sure what part or components, but I am experiencing a smell of some kind that is making me sick. As in, nausea, vomiting, sleepiness, headaches and migraines. This only happens when I am in the vehicle and only at certain times throughout the day. I've been vacationing for several months now and this is a reoccurring problem. When I am driving the smell is trying to put me to sleep and I have to pullover on the interstate to sleep and I have been putting the windows down to try to stop the reactions I am having. But, the smell continues even when the engine is not running. That is the best way I can explain the experience that I am having. Thank you so much and have an absolutely amazing day.

NHTSA ID

11464151

Incident

Mar 1, 2022

The contact's wife owns a 2015 Ford Fusion. The contact previously had the canister purge valve replaced on three separate occasions. The contact stated that while his wife was driving at an undisclosed speed, the vehicle lost motive power. The vehicle was taken to an independent mechanic and diagnosed with a cracked fuel tank. The mechanic informed the contact that the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 76,000.

NHTSA ID

11462238

Incident

Apr 26, 2022

Mileage

76,000 mi

Coolant leak into the cylinders. Car overheating due to low coolant.

NHTSA ID

11461204

Incident

Apr 18, 2022

As I was driving, it felt as if my car had turned off or had no fuel, but no engine lights came on and i had fuel in my tank. Also all my electrical stuff stayed on, only lost power on the accelerator. My safety and others safety was put at risk because there were no warning signs i just had no "Go power" and no one around me knew my car had no power which could lead to an accident, serious injury or death; if on highway traveling at high speeds and it randomly dies. I took my car to a mechanic and they stated everything was perfectly fine they did a full diagnostic and the computer didn't show any errors in operation. This happened 3 times in one day at random times, i could put the car in park and re-start and it ran fine. however i did have to hold the key forward longer for the engine to turn over.

NHTSA ID

11458065

Incident

Mar 20, 2022

The contact owns a 2015 Ford Fusion. The contact stated while driving at 25 MPH, the vehicle stalled. The contact did not notice any warning lights on the first failure, but in subsequent failures the check engine warning light illuminated. The contact stated that additionally there was a suction noise that started coming from the fuel cap when the vehicle would stall. The contact took the vehicle to the local dealer, where it was diagnosed that the purge valve needed to be replaced. The vehicle was repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 88,000.

NHTSA ID

11455095

Incident

Nov 15, 2021

Mileage

88,000 mi

THE CAR IS BURPING IN THE GAS CAP. IT IS VERY DIFFICULT TO START AFTER FUELING. AND WILL RANDOMLY SHUT OFF. CHECK ENGINE LIGHT IS ON. CODE P1450 $07E8PD & P1450 $07E8. I CLEAR THE CODE AND IN A DAY.OR SO IT COMES BACK ON. THIS STARTED AROUND 78K MILES. I HAVE 79201. ON MY CAR. PLASTING A TIGHT PLASTIC WRAP OVER THE TANK REDUCES BURPING AND RANDOM SHUT OFF.. THIS IA A MAJOR REPAIR FOR A CAR WITH THIS MILEAGE LOCAL NON INTERSTATE MILES. THAT HAS BEEN WELL CARED FOR. THIS SEEMS TO BECA COMMON PROBLEM FOR THE FUSION BASED ON INTERNET SEARCH.

NHTSA ID

11408623

Incident

Mar 2, 2021

Mileage

78,562 mi

FUEL SYSTEM LOSES PRESSURE SOMETIMES AND THE CAR CUTS OFF COMPLETELY, SOMETIMES AT HIGH SPEEDS. THIS IS VERY DANGEROUS BECAUSE OF LOSS OF POWER STEERING AND BRAKES. THAT TRANSMISSION ALSO SHIFTS ERRATICALLY SOMETIMES WHICH IS ALSO DANGEROUS BECAUSE IF I NEED TO ACCELERATE TO AVOID AN ACCIDENT, IT WONT SHIFT CORRECTLY AND MAKES IT MORE DIFFICULT TO DO SO.

NHTSA ID

11405081

Incident

Mar 26, 2021

Mileage

95,000 mi

CHECK ENGINE LIGHT ON, HONING COMING FROM REAR DRIVER SIDE, AFTER FILLING WITH GAS THE ENGINE FIRES UP PROPERLY BUT THEN SPUTTERS OUT, CODES ARE READING EVAPORATOR PURGE SYSTEM FAILURE

NHTSA ID

11403543

Incident

Mar 12, 2021

Mileage

79,000 mi

THE AFFECTED VEHICLE IS A 2015 FORD FUSION ENERGI WITH 80,350 MILES. VIN: 3FA6P0SU1FR I PURCHASED THE VEHICLE FROM KELLER FORD IN HANFORD CALIFORNIA ON 11JAN2021, AT 79,902 MILES. ON MY WAY TO WORK WHILE ON THE HIGHWAY, SYMPTOMS STARTED WITH A HIGH PITCH NOISE, FOLLOWED BY, A BURNING SMELL, MOTOR OVER TEMP WARNING, AND FINALLY A COMPLETE LOSS OF POWER AND A "PULL OVER SAFELY" WARNING. I HAD MY CAR TOWED TO THE DEALERSHIP THE FOLLOWING MORNING TO BE WORKED ON, WHERE THEY FOUND THE TRANSMISSION ASSEMBLY TO BE THE AFFECTED ISSUE. THE TRANSMISSION HAD BEEN REPLACED SOMETIME LAST YEAR PRIOR TO MY OWNERSHIP, WHICH WAS UNDISCLOSED TO ME AT THE TIME OF PURCHASE, SO THIS IS NOW THE SECCOND TIME THIS CAR HAS HAD AN ISSUE WITH THE ECVT ASSEMBLY. (PART NUMBER HM5Z-7000-ARM). THE ORIGINAL REPAIR WAS A COMPLETE TRANSMISSION REPLACEMENT, BUT THIS TIME, FORD IS LOOKING AT HAVING THE DEALERSHIP REBUILD THE TRANSMISSION. I HAVE NOT BEEN ABLE TO FIND MANY OTHER ISSUES WITH THIS TRANSMISSION, ASIDE FOR TWO TSBS. 20-2219 AND 19-2391. THE HYBRID ELECTRICAL SYSTEM, WHICH INCLUDES THE ECVT, IS WARRANTED BY FORD UP TO 8 YEARS OR 100,000 MILES

NHTSA ID

11395854

Incident

Jan 27, 2021

Mileage

80,350 mi

8/15/2019 MY SON TOOK MY CAR TO AUTO CLINIC OF BOCA RATON INC.=COMPUTER DIAGNOSTIC SCAN, NO CHARGE=REPLACED CYLINDER TO IGNITION COIL-TOTAL WAS $90.95(12MONTH OR 12,000MILES LIM. WARTY.). ON 10/24/2019 MY SON TOOK MY CAR TO THE GRAYCO FORD OF DELRAY BEACH FOR RECALLS. ENGINE LIGHT WAS BACK ON,THEY WANTED $TO FIND OUT Y THE LIGHT WAS ON. SO MY SON LEFT &ON HIS NEXT DAY OFF HE TOOK THE CAR BACK TO THE AUTO CLINIC AGAIN. THEY DID A DIAGNOSTIC SCAN=FREE&THIS TIME=REPLACED CYLS.1,3&4 IGNITION/COILS= $272.85 THIS TIME MILEAGE IN & OUT WAS 53,473. MY SON MILEAGE IN FOR MY CAR AT GRAYCO FORD OF DELRAY BEACH WAS 54,824 ON 10/24/19. MOTOR WAS UNDER WARRANTY UP UNTIL 60,000 MILES. SO I DON'T UNDERSTAND WHY THEY WOULDN'T OF LOOKED AT THAT CHECK ENGINE LIGHT OR THE MOTOR OF MY CAR FOR MY SON WHO WAS AWAY AT COLLEGE IN FLORIDA FOR 3YRS. I BOUGHT THAT CAR IN ORDER FOR HIM TO GO TO FLORIDA AND WORK AND GO TO SCHOOL LYNN UNIVERSITY TO GET HIS MASTERS DEGREE AT 23 YEARS OLD. I THOUGHT I BOUGHT A SAFE VEHICLE FOR HIS TRAVELS. MY SON GOT HIS NORMAL OIL CHANGE OF EVERY 3 MONTHS ON 4/15/20@1:03PM. ENGINE LIGHT ON AFTER HE LEFT SO HE TOOK IT TO THE AUTO CLINIC AGAIN @2:05 THEY REPLACED SPARK PLUGS FOR $58.44 MILEAGE IN 58,325 IN AND OUT. HE MOVED HOME TO OH THE CHECK ENGINE LIGHT ON AGAIN! I TOOK IT TO CLASSIC,MENTOR OH THEY TELL ME MY FORD ENGINE HAS A PROBLEM SOMETHING WARPS INSIDE A CHAMBER AND LETS COOLANT GO INTO THE MOTOR! THEY WANT $5200 TO FIX IT. I CALLED FORD&IT'S 2000 MILES OUT WARRANTY. THEY SAID CAN'T/WON'T HELP W/ THIS WELL-KNOWN PROBLEM FOR 2013-2019 FUSIONS! I TALKD TO THE GRAYCO FORD OF DELRAY, VERY RUDE (DAVID ALIVA) & BOSS VERY RUDE AS WELL. I GOT A RUDE EMAIL,THAT THEY WILL NOT HELP ME! EVEN THOUGH THE CHECK ENGINE LIGHT WAS ON AND IT WAS UNDER 60,000 MILES! CAR SITTING AT MENTOR CLASSIC(SINCE 08/20)THEY TELL ME IT IS A FIRE HAZARD TO DRIVE! I DON'T KNOW WHAT TO DO!

NHTSA ID

11376379

Incident

Aug 2, 2020

WHEN GETTING READY TO PARK THE CAR THE CAR SAYS IT'S IT NUETRAL BUT IT'S ACTUALLY I BELIEVE IN PARK. I TOOK MY FOOT OFF THE BREAK AND IT WAS MOVING BACKWARDS. I PUT THE PARKING BREAK ON THE CAR SO IT IS STATIONARY.

NHTSA ID

11374735

Incident

Nov 14, 2020

Mileage

144,038 mi