2018 Ford Fusion Other / unspecified Problems

Ford's double-capped acorn lug nuts experienced outer cap expansion/separation during an emergency roadside tire change. A defective design known by Ford. Rendering the supplied tire iron and a separately purchased multisize tire iron ineffective at removing the lugs. The failure left the vehicle immobile on the side of a i75 in SWFL in the summer heat of June 2026. Present in the vehicle were the owner, spouse, and a [XXX] infant. They were stranded approximately 34 miles from home for nearly 3 hours, an extended period for a XXX, who quickly became visibly distressed. Standard FDOT Road Ranger assistance was unavailable, and towing services had estimated wait times exceeding 2 hours. The driver was unable to resolve the situation through any reasonable self-help measure due to the defective lugs, despite having successfully changed tires on the same vehicle previously using the same factory equipment. The defect was verbally identified during the incident by a responding AAA roadside technician. They recognized the defect as consistent with a known issue affecting Ford vehicles. No formal inspection by Ford Motor Company, law enforcement, or insurance representatives has taken place but will be pursued by the owner and available for inspection is requested. No warning lamps, dashboard alerts, or observable symptoms were present that would have indicated a lug nut defect to the owner. It only became apparent at the moment an emergency tire change was required. This is consistent with prior reported cases and litigation involving Ford. The owner was never informed of this defect during the vehicle purchase, service history, or extended warranty agreement. If known road side assistance would have been contacted, instead of self servicing the tire change which was rendered useless by a defect Ford has been aware of. Resulting in nearly 3 hours of preventable roadside exposure, emotional distress, and the endangerment of a [XXX] infant. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C.

NHTSA ID

11743999

Incident

Jun 13, 2026

The contact owns a 2018 Ford Fusion. The contact stated that while driving at various speeds, the vehicle shuddered upon depression of the accelerator pedal. The contact stated that while at a complete stop, there was an abnormal popping sound coming from the vehicle while depressing the accelerator pedal. The failure persisted, and the contact stated that the steering wheel was loose while operating the vehicle. The contact stated that the traction control warning light flashed on the instrument panel during one of the failures. The vehicle was not yet diagnosed or repaired. The manufacturer was notified of the failure and informed the contact that there were no recalls on the VIN related to the failure of the vehicle. The contact was referred to the NHTSA Hotline to report the failure. The failure mileage was approximately 41,000.

NHTSA ID

11666258

Incident

May 11, 2025

Mileage

41,000 mi

Went to got a normal free oil change. They told us they could not do a tire rotation because the lug nuts were swollen. On a 2018 car the cheap 2 piece lug nut swollen so a normal 19mm socket could not fit over to took off the tire. No recall and no free fix at the Anderson SC Ford Dealer.

NHTSA ID

11578322

Incident

Mar 15, 2024

The contact owns a 2018 Ford Fusion. The contact stated during a routine oil change and tire rotation, the contact was informed that the lug nuts were swollen and needed to be cut off to be removed. The vehicle was not repaired. The manufacturer was informed of the failure. The failure mileage was approximately 58,000.

NHTSA ID

11559582

Incident

Dec 11, 2023

Mileage

58,000 mi

Went to have car serviced and was told lug nuts were swollen and it was a Ford defect, but had to pay over $120 to replace lug nuts in order to get my tires rotated.

NHTSA ID

11559387

Incident

Dec 9, 2023

lug nuts are swollen and lug nut wrench does not fit on lug nuts. Had to get special tool to remove flat tire and replace lug nuts

NHTSA ID

11524400

Incident

May 30, 2023

Replacing tires for the first time in this vehicle & all lug nuts on each tire is swollen. Reached out to Ford & they advised to file a complaint as my vehicle is not recalled for this at this time but there is a recall for swollen lug nuts under 22S59

NHTSA ID

11517658

Incident

Apr 18, 2023

The caps on the lug nuts fall off then the lug wrench does not fit, and the caps twist and now the dealer is charging me add to get then off, and usually I have to pay for some and it just happens again and again.lug nuts are 15.00 each.

NHTSA ID

11517652

Incident

Mar 16, 2023

At a. Recent appointment at local Ford dealer, I was told that tires could not be rotated due to swollen lug nuts. I perceive that as a safety concern as in event of a flat out out on the road, I would be stranded. Dealer quoted a price of over $250 to replace. Seems to me that this should be Fords responsibility. I feel uneasy driving my Fusion now.

NHTSA ID

11489433

Incident

Oct 13, 2022

Had tires replaced and mechanic reported several swollen lug nuts.

NHTSA ID

11446575

Incident

Jan 6, 2022

RECENTLY BROUGHT VEHICLE IN FOR OIL CHANGE AND TIRE ROTATION TO FARNEY FORD IN SELMA, CA DEALERSHIP AND WAS TOLD THAT THE LUG NUTS EXPANDED AND CANNOT BE REMOVED. THEREFORE I WOULD HAVE TO PAY TO HAVE 5 LUG NUTS REPLACED ON ALL 4 FACTORY INSTALLED TIRES IN ORDER TO GET A TIRE ROTATION. THE VEHICLE HAS GONE IN FOR TIMELY OIL CHANGES AND DID HAVE TIRE ROTATION DONE BY THE FARNEY FORD DEALERSHIP WITHIN THE PAST 15 MONTHS. WE DID PUT A COMPLAINT IN AND WAS ASSIGNED A CASE NUMBER FROM FORD. 5 DAYS LATER AND STILL NO RESPONSE. WHAT WILL HAPPEN IF I GET A FLAT AND CAN'T GET THE LUG NUTS OFF? WE LIVE IN A FARMING TOWN AND TRAVEL THROUGH BACK ROADS TO GET IN TO FRESNO, CA.

NHTSA ID

11320103

Incident

Mar 30, 2020

Mileage

36,000 mi

THERE'S A LEAK IN THE VALVE STEM ON THE FRONT RIGHT TIRE.

NHTSA ID

11234653

Incident

Jul 10, 2019