2015 Ford Fusion Other / unspecified Problems

To keep it short. This is 1 of 3 Ford vehicles that I had to pay to have every lug nut replaced! They are 'swollen' is the term used. Prior to this, I replaced 1 lug in my 45 year driving history and that was because it broke off. I have called Ford and Lincoln and they are aware of the problem but say there is not program in place for a resolution. My complaint was escalated I was told. Hahaha. Their hand needs to be forced. They are not going to willingly do the right thing going forward nor address refunds! They have 'escalated' all 3 of my issues. I would imagine that there is a fourth coming at some point when my daughters car needs to go into the shop. $250+ a car is a joke and an expense nobody needs. Please help. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11652322

Incident

Feb 2, 2021

The contact owns a 2015 Ford Fusion. The contact stated while the vehicle was at the dealer for a scheduled tire rotation, the contact was informed that the lug nuts were swollen. The contact was informed that the lug nuts needed to be replaced. The vehicle was repaired. The contact stated that a torch was used to remove the lug nuts. In addition, the contact was informed that the failure was a known issue. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 40,000.

NHTSA ID

11622758

Incident

Oct 29, 2024

Mileage

40,000 mi

Took vehicle to Ford dealership for routine maintenance 5 June 2024. At end of servicing, service advisor reviewed findings of the multi-point inspection with me (attached), advising all wheel lug nuts (20) on the vehicle were "swollen" and needed to be replaced; failure to do so will result in being unable to remove any wheel in the event of an emergency, i.e., flat tire, as the provided 19" lug nut wrench ( or any substitute 19" socket will not fit). Quoted price of $337.60 for nuts ($447.52 incl labor). I passed. Ordered one piece chrome lug nuts (20) for $40, and a $45 half size socket set (19.5mm) online and changed them myself. Research on the issue reveals Ford is aware of this safety defect of two piece swelling lug nuts, yet refuses to recall affected vehicle or remedy the safety issue. All affected vehicles need to be recalled and corrected by Ford immediately, our lives/safety is at risk with this issue.

NHTSA ID

11596031

Incident

Jun 5, 2024

Took the car in to have a tire replaced and was told the swollen lug nuts prevent them from removing the tire. I had issues with lug nuts on another wheel but was able to get them off and replaced them. I shouldn't have to be paying $27 for lug nuts that are defective.

NHTSA ID

11591244

Incident

May 24, 2024

Took my car to the dealership for an oil change and tire rotation. The technician told me they cannot get the tires off to rotate them because the tire lug nuts were swollen. He asked me if I wanted to replace them. I agreed after he said that if I were to get a flat tire it would be hard to get it off to fix it. Basically, this issue became a safety one. I never had an issue with swollen lug nuts with previous cars I had own. Thank you for gathering these type of issues.

NHTSA ID

11589463

Incident

May 18, 2024

When taking my car in for regular servicing, I was told that the tires could not be rotated because of swollen lug nuts. My vehicle has 11,777 miles. Without proper tire rotation, I cannot effectively drive safely without risk to myself and others. So, I opted to have the lug nuts replaced in fear of future problems should I need to remove a tire. Not being a mechanic, I have no idea what constitutes the look or feel of swollen lug nuts. My car was serviced on March 12 and 13, 2024 at the cost of $381.86 (lug nuts: $257.35)

NHTSA ID

11577141

Incident

Mar 12, 2024

Car was taking him for a recall on brake lines. Dealer phoned me and suggested that they replace the Lugnuts because they are a two piece. They are swollen and it’s a safety issue. I agreed to have them replace them at my cost because there is no warranty on these defective Lugnuts I see that this is an ongoing issue that Ford has known for quite a while. I think they should reimburse the people for the money they have spent on the dealer charges or just warranty them for the rest people that come in with the same issue. I also believe that my dealer is way over charging 10 Lugnuts will be about $100 for me to pay whereas I can buy a set of 20 of them online for under $20. I think this is outrageous.

NHTSA ID

11550851

Incident

Oct 19, 2023

I am here to have safety recall(s) performed on my 2015 Ford Fusion. They cannot do the recall without changing defective (rusted lug nuts) at a cost of $160.00. Rusted lug nuts seem to be an issue with this model car and I feel should be covered as part of the recall if the replacement of the lug nuts is required to perform the recall safety service.

NHTSA ID

11538571

Incident

Aug 15, 2023

I was driving on the freeway yesterday, about 70mph driving conditions were good, it was sunny and warm, and traffic was flowing regularly, and I felt as thought something gave way or loosened up because the car and steering ability were not in synch. I was then approaching a congested area and needed to slow down but the brakes did not brake as fast as they should of and I almost smashed right into the car in front of me. There felt like a disconnection between the brakes, the steering, and the entire car. I have keep my care well maintained and do not miss my regular maintenance appointments. I just had it smogged, with a change of oil and 80k inspection. The tires were checked and everything was ok. There were no indicator lights or alerts however, I do have a light that will not shut off and i was told subject to a recall. It's the front fog lights? or running lights? its the front lights not head lights but the ones the side. That light doesn't impact my driving ability. This is a very unsafe and frightening experience and I would like it investigated before someone really gets hurt.

NHTSA ID

11518087

Incident

Apr 19, 2023

Service department said that the Ford Fusion lug nuts are swelling and need to be replaced. Said they may be hard to get off or they could crack and break. I fill this should be a cost that Ford should pay or replace them for me. Not at my cost.

NHTSA ID

11494108

Incident

Nov 18, 2022

2015 FORD FUSION. CONSUMER WRITES IN REGARD TO FAULTY LUG NUTS. THE CONSUMER IS REQUESTING TO BE REIMBURSED FOR THE FAULTY LUG NUTS.

NHTSA ID

11493673

Incident

Nov 15, 2022

The contact owns a 2015 Ford Fusion. The contact stated that the lug nuts on all four wheels were corroded and swollen. The contact was concerned that in the event of a flat tire or blowout, the lug wrench would be unable to remove the swollen lug nuts. The vehicle was taken to the dealer where it was diagnosed that all the lug nuts needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 52,000.

NHTSA ID

11484444

Incident

Mar 1, 2022

Mileage

52,000 mi

Swollen lug nuts and couldn’t get the drivers side front tire off at Ford dealership. I had to take my vehicle to Discount tire for them to get the lug nut off and replace all lug nuts.

NHTSA ID

11466688

Incident

May 28, 2022

When replacing a flat tire it was noted that the lug nuts are swelling and distorted. The mechanic said they must be replaced as it is a safety hazard.

NHTSA ID

11453661

Incident

Feb 17, 2022

Swollen lug nuts. 100,000 miles on vehicle. Had tires rotated at discount tires. They had a very hard time removing swollen lug nuts. Had to spend $60 to replace whole set.

NHTSA ID

11446353

Incident

Jan 5, 2022

The contact owns a 2015 Ford Fusion. The contact stated that the driver’s side front tire lost air and became flat, but the independent mechanic was unable to remove the wheel from the vehicle due to the lug nuts being swollen. The vehicle was later taken to the local dealer who replaced the lug nuts. The cause of the failure was not determined. The manufacturer was not yet contacted. The failure mileage was 48,000.

NHTSA ID

11426494

Incident

Jul 5, 2021

Mileage

48,000 mi

THE LUG NUTS MAKE IT IMPOSSIBLE TO REMOVE WITH EITHER THE TOOL FORD PROVIDED, A 4 WAY WRENCH OR SOCKETS WHEN I GOT A FLAT. I COULD HAVE BEEN KILLED FIGHTING WITH THIS ON THE SIDE OF THE ROAD. I BELIEVE FORD SHOULD HAVE TO REPLACE ALL OF THESE LUG NUTS AS A SAFETY CONCERN SINCE THEY ARE DEFECTIVE.

NHTSA ID

11310845

Incident

Feb 16, 2020

Mileage

59,000 mi

I WAS DRIVING BACK FROM GROCERY SHOPPING WHEN I LOST CONTROL OVER STEERING. THE MOMENT WHEN I LOST CONTROL WAS DURING MY SLIGHT RIGHT TURN MOVING AT SPEED OF ABOUT 30MPH I DID NOT KNOW WHAT HAPPENED AT THE MOMENT BECAUSE I WAS MORE FOCUSED TO NOT HIT ANYONE PRESENR AT THAT MOMENT ON THE ROAD. GOOD THING IS THAT SCHOOL ACROSS THE ROAD WAS CLOSED BECAUSE TIMING WHEN THIS HAPPEN WAS AROUND THE TIME WHEN PARENTS USUALLY PICK THEIR KIDS FOR SCHOOL. AFTER I PARKED CAR I INVESTIGATE TO SEE WHAT HAD HAPPEN. THERE WERE THREE MESSAGES INDICATING THAT SOMETHING WAS WRONG: 1. STEERING ASSIST FAULT - SERVICE REQUIRED, 2. SERVICE ADVANCETRAC AND 3. HILL START ASSIST NOT AVAILABLE. I WAS SEARCHING TODAY TO SEE OTHER PEOPLE EXPERIANCE AND RESULTS WERE POSITIVE A LOT OF CASES LIKE THIS ONE. THINGS THAT ALL REPORTS HAVE IN COMMON IS THAT ALL OWNERS NEEDED TO PAY TO FIX CAR NO OPTION FOR RECAL. EVENTHOUGH THAT MODELS LIKE THIS ONE USED TO HAVE SEVERAL THINGS THAT NEEDED TO BE CHANGED ON SIMILAT THINGS IN THE PAST.

NHTSA ID

11291419

Incident

Dec 26, 2019

Mileage

69,407 mi

THE CAR JERKS DURING SHIFTING ON CITY STREETS, ALL TIMES OF DAY, ALL ROAD CONDITIONS.

NHTSA ID

11144835

Incident

Feb 23, 2018

Mileage

37,692 mi

AFTER TAKING MY 2015 FORD FUSION FOR A TRANSMISSION PROBLEM AND OTHER RECALLS THEY KEPT THE CAR FOR OVER A MONTH WITH NO RENTAL PROVIDED WHEN I FINALLY GOT IT BACK FROM THE SPEED OF 15 TO 30 THE PASSENGER SIDE STARTING MAKING NOISES AND COULD FEEL THE VIBRATION FROM IT AND 55 AND UP IT JUST GETS WORSE.

NHTSA ID

11142773

Incident

Jun 19, 2018

Mileage

63,000 mi

THERE HAS BEEN MANY ISSUES WITH THE FRONT END OF MY CAR. BOTH STRUTS HAVE BEEN REPLACED AT 22,000 MILES. THE SWAY BAR LINK WAS ALSO REPLACED.I AM NOW AT 23,000 MILES EXPERIENCING A NOISE LIKE A BALL JOINT CLUNKING IN THE PASSENGER FRONT AND THE DEALERSHIPS CANNOT FIGURE OUT WHAT IS MAKING THE NOISE. I HAVE BROUGHT IT TO 2 SEPARATE DEALERSHIPS FOR A SYNOPSIS. STILL NOTHING. ALSO, THE TRANSMISSION SHIFTS VERY ROUGH AND SLAMS INTO THE NEXT GEAR FROM 2-3. I PURCHASED THIS CAR FROM SPORT AUTOMOTIVE USED CARS ON OCTOBER 2017. EVER SINCE NOTHING BUT ISSUES. VERY DISSATISFIED WITH THIS VEHICLE. ESPECIALLY SINCE FORDS HAVE ALWAYS BEEN PURCHASED IN MY FAMILY.

NHTSA ID

11045981

Incident

Oct 14, 2017

WHILE DRIVING HOME ON I- 55, ONE OF MY BACK TIRES BLEW UP ON 2015 FORD FUSION. THIS NEARLY CAUSED A POTENTIALLY FATAL ACCIDENT! ON SATURDAY, I CALLED MICHELIN, THE MANUFACTURER OF THE TIRE AND THEY TOLD ME TO TAKE THE TIRE TO DISCOUNT TIRE. I WENT IN TO DISCOUNT TIRE IN NEW LENOX, IL ON SATURDAY FEBRUARY 11, 2017, AND THE MANAGER NEAL, SAID THAT ALL OF THE TIRES NEEDED TO BE REPLACED, AND THE BLOWOUT WAS CAUSED AS A RESULT OF LOW THREAD COUNT. DISCOUNT TIRE WENT ON TO INFORM THAT XCHANGE LEASING, WHO IS RESPONSIBLE FOR SAFETY AND INSPECTION OF THE VEHICLE WOULD BE RESPONSIBLE FOR MISSING THE NEED FOR THE TIRES TO BE REPLACED. SUBSEQUENTLY, IT SEEMS THAT XCHANGE HAS DROPPED THE BALL, AND THANKFULLY THE NEGLIGENCE DID NOT RESULT IN AN UNTIMELY DEATH! SINCE, BEING A PART OF THE XCHANGE LEASING PROGRAM, I HAVE REGULARLY HAD ALL OF MY INSPECTIONS COMPLETED, WHICH INCLUDED TIRE ROTATION, AND INSPECTION. THERE IS NO INDICATION ON ANY OF THE INSPECTION REPORTS THAT TIRES NEED TO BE REPLACED. I AM CURRENTLY DRIVING ON A DONUT, AND I AM SEEKING A RESOLUTION TO THIS PROBLEM.

NHTSA ID

11012370

Incident

Feb 10, 2017

Mileage

50,000 mi

RECENTLY, WHILE TRAVELING FROM CHICAGO, IL TO LAS VEGAS NEVADA, I EXPERIENCED MECHANICAL ISSUES WITH MY 2015 FORD FUSION. THE CAR BROKE DOWN IN LAS VEGAS, NEVADA, WHERE I TOOK IT TO A LOCAL REPAIR SHOP, DUE TO THE CLOSENESS OF THE WHERE IT BROKE DOWN. THE REPAIR SHOP STATED THAT THEY WOULD NEED A FEW DAYS TO DIAGNOSE THE VEHICLE. UNFORTUNATELY, I HAD NO MORE DAYS TO STAY IN VEGAS, AS I NEEDED TO RETURN HOME. THUS, I FLEW BACK TO CHICAGO, AND LEFT MY CAR IN LAS VEGAS, NEVADA IN THE CARE OF THE REPAIR SHOP FOR TESTING AND DIAGNOSIS AND REPAIR. THE REPAIR SHOP CALLED AND STATED THAT MY CAR NEEDED A NEW TRANSMISSION. THIS BEFUDDLED ME, AS MY CAR WAS JUST BARELY TWO YEARS OLD AND HAS LOW MILEAGE. UPON DOING SOME RESEARCH, I FOUND THAT FORD FUSIONS FROM 2013-2016 HAVE KNOWN MECHANICAL ISSUES WITH THE TRANSMISSION AND MANY HAVE ALREADY BEEN RECALLED. I CALLED THE FORD CORPORATE OFFICE AFTER THE REPAIR SHOP ADVISED THAT THE TRANSMISSION NEEDED REPLACING. I WAS ADVISED TO HAVE THE VEHICLE TOWED TO A FORD DEALERSHIP. I HAD THE CAR TOWED TO FRIENDLY FORD, WHERE I AM WAITING FOR THE DIAGNOSIS TO BE COMPLETED. HOWEVER, I WAS ALREADY ADVISED THAT IF IN FACT THE TRANSMISSION NEEDS TO BE REPLACED, IT WOULD BE TAKE APPROXIMATELY 4-6 WEEKS TO BE COMPLETED. THIS PRESENTS A TREMENDOUS INCONVENIENCE TO ME, AS I AM IN CHICAGO AND MY VEHICLE IS 1800 MILES AWAY FROM ME, ESSENTIALLY USELESS TO MY DAY TO DAY ACTIVITIES WHICH INCLUDE SCHOOL, WORK, DOCTORS' APPOINTMENT ETC. I AM A FULL-TIME STUDENT, AND WORK FULL TIME. UNFORTUNATELY, RECENTLY I HAVE BECOME VERY ILL AND HAVE HAD TO CATCH RIDES TO MY VARIOUS DOCTORS' APPOINTMENTS. GETTING AROUND HAS BEEN SIGNIFICANTLY CHALLENGING WITH NO VEHICLE. I BELIEVE THAT FORD KNEW THAT THERE WERE TRANSMISSION FAILURES ON AND FAILED TO RECALL ALL OF THEM TO SAVE MONEY, AND AVOID EXPENSIVE REPAIR COSTS ON POORLY

NHTSA ID

11012368

Incident

Jul 10, 2017

Mileage

58,000 mi