2020 Ford Fusion

The contact owns a 2020 Ford Fusion. The contact stated that while driving, the check engine warning light illuminated. A diagnostic test was performed by an independent mechanic, and the failure was associated with the catalytic converter. The catalytic converters were replaced twice; however, the failure persisted. The manufacturer was notified of the failure and informed the contact that the replacement part was no longer produced, rendering the vehicle unrepairable. The failure mileage was approximately 175,000.

NHTSA ID

11775580

Incident

Aug 15, 2026

Mileage

175,000 mi

COMPONENT/SYSTEM: Gasoline vapor entering the occupied passenger cabin through the HVAC vents during and after rain with the A/C or heat on. Root cause unidentified, not because it cannot be found, but because Ford Motor Company has not once tested the vehicle under the condition in which the defect occurs, and has refused in writing to assign an engineer who would. Suspected fuel system / evaporative emissions / cowl-to-HVAC intake pathway. Vehicle available to NHTSA for inspection on request. SAFETY RISK: The driver and passengers breathe gasoline vapor inside a closed, moving vehicle. Fuel vapor in an occupied cabin is an inhalation hazard and an ignition hazard. The owner drives with the windows open to vent it. Ford’s own agent acknowledged in writing on 09/24/2026: “I understand that your vehicle currently has a gas odor and you do not feel safe driving it.” Ford has since returned the vehicle to the owner unrepaired four times, has never stated it is safe to drive, and has stated in writing that it is closing the case. The vehicle is on the road today with the defect present. If this condition exists on other Fusions, those owners cannot rely on Ford’s dealer network to detect it, because Ford’s diagnostic procedure, as applied four times to this vehicle, does not test for it. REPRODUCED/CONFIRMED BY DEALER: YES, BY FORD’S OWN DEALER, IN WRITING. Serra Ford Farmington Hills, authorized Ford dealer, repair order [XXX], opened 07/17/2026, 45,535 miles: “CUSTOMER STATES GAS SMELL FROM AC DUCT WHEN AC IS BLOWING FULL BLAST, VERIFIED ON DRIVE.” The advisor drove the vehicle and smelled it. First reported to the same dealer 06/23/2026, RO [XXX]: gas smell inside the cabin after rain, from the AC/heat. Ford Motor Company Customer Relations supervisor Juan Garza confirmed in writing on 10/21/2026: “I reviewed the July 17 repair order language stating that the concern was ‘verified on drive.’” The next day, 10/22/2026, the same supervisor recharacterized the same INFORMATION REDACTED PURSUANT TO THE FREEDOM OF I

NHTSA ID

11773688

Incident

Jun 23, 2026

Our 2020 Ford Fusion automatically shifts back into Park and displays the "Shift Sys Fault" error message, the primary culprit is a broken transmission shift cable bushing. Vehicle may be in gear and unable to stop itself from rolling on an incline unless parking brake is applied.

NHTSA ID

11772436

Incident

Oct 20, 2026

The contact's brother owns a 2020 Ford Fusion. The contact stated that while the owner was driving 35 MPH, the engine overheated and there was misfire coming from the engine. The check engine warning light illuminated, and there was fluid leaking into the engine. An independent mechanic was contacted by phone. The vehicle was taken to the independent mechanic and was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The contact was informed that the failure was a known failure with the vehicle. In addition, the contact was informed that the failure was due to the manufacturing design of the engine. The manufacturer was contacted by phone and a case was filed. The failure mileage was approximately 72,000.

NHTSA ID

11767353

Incident

Aug 28, 2026

Mileage

72,000 mi

2020 Fusion SEL with 41,000 miles. While driving at 65 mph with adaptive cruise control engaged, the vehicle suddenly jerked on two separate occasions during a three-hour drive.

NHTSA ID

11766198

Incident

Sep 22, 2026

I recently acquired this vehicle from a dealer after the previous owner traded it in and after reviewing the Carfax I did some deeper digging into this vehicle and discovered that there are 3 recalls that have not been serviced. I am hoping that there wasn't any secondary damage due to the recalled items as I haven't noticed anything necessarily wrong with the car but I figured I'd take it in to be safe. I also want a quote for a transmission drain and fill, NOT A FLUSH. The transmission is shifting fine, I just am looking to get it done as preventative maintenance and for peace of mind. The recall repairs are noted in the PDF attached below.

NHTSA ID

11765718

Incident

Sep 19, 2026

Coolant Intrusion. Started with thick white exhaust when starting up in morning. Turned into acceleration lags, car shutting engine off when parked, and exhaust smell coming inside of car. 2014-2019 models have a recall for cracked engine block allowing cooling to leak inside, but 2020 models do not although there is an increased problem with this year and model of car.

NHTSA ID

11764867

Incident

Sep 16, 2026

The contact owns a 2020 Ford Fusion. The contact received notification for NHTSA Campaign Number: 23V440000 (Electrical System); however, the part to complete the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The dealer was made aware of the issue and confirmed that parts were not yet available.

NHTSA ID

11764621

Incident

Jun 16, 2023

Special Field Action 26L03 Certain 2013-2024 Model Year California Emissions-Certified Vehicles Transmission Fluid Auxiliary Pump Reimbursement

Certain 2021-2024 Model Year Bronco, 2021-2024 Model Year Bronco Sport, 2020-2022 Model Year Corsair and Escape, 2016-2024 Model Year Explorer, 2019-2020 Model Year Fusion, 2016-2018 Model Year Focus RS, 2022-2024 Model Year Maverick, 2016-2019 Model Year MKC and 2019-2024 Model Year Ranger Vehicles Equipped with a 2.0L or 2.3L Engine and Engine Block Heater System Block Heater Replacement

Harvest Program 25H05 – Supplement #1 Certain 2011-2021 Model Year Vehicles Software Verification Harvest Program

Ford and Lincoln vehicles equipped with wired keyless entry keypad systems and accessory wireless keyless entry keypad systems may or may not come with a wallet card containing the master code. Unlike the integrated wired keypad, the accessory wireless keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool or from the label printed on the body control module (BCM). The Factory Keyless Entry Code application within the diagnostic scan tool will not provide an applicable master code for the accessory wireless keypad. If the wallet card for an accessory keypad is not available, the "Wireless RF Keypad Diagnosis Guide" can be referenced and provides direction on how to retrieve the master code. This guide is located under the Workshop Manual tab > Accessories > Installation > Wireless RF Keypad Diagnosis Guide > PPT C > Step C2.<br /><br /> Note: The only available keypad for some vehicles from the assembly plant is the accessory wireless keyless entry keypad. The integrated wired keypad cannot be installed on vehicles not equipped from the factory with a wired keyless entry k

Some 2019-2024 Ford and Lincoln vehicles equipped with SYNC3 may experience various connectivity concerns with The Ford App Lincoln App including but not limited to: missing activation prompt pop-upon the vehicle's center display screen when attempting to activate vehicle through The Ford App Lincoln App, incorrect location global positioning system GPS reported through The Ford App Lincoln App, problems with remote commands being performed through The Ford App Lincoln App and or incorrect data information reported on The Ford App Lincoln App. These symptoms will be accompanied by diagnostic trouble code DTC B156D 89 in the TCU. This may be due to the accessory protocol interface module APIM software. To correct the condition, update the APIM software.

This is a proactive investigation program by Ford Motor Company to inspect a limited number of affected vehicles that are customer-owned. Ford is voluntarily conducting this program to evaluate the software currently installed on one or more electronic modules in the affected vehicles.