2011 Mercury Milan

The Office of Defects Investigation (ODI) opened a preliminary evaluation to investigate complaints of the loss of power steering while driving. The subject vehicles are equipped with a rack mounted Electric Power Assisted Steering (EPAS) unit.Some of the complaints alleged that the steering assist failed and resulted in increased steering efforts that contributed to a loss of control and in some cases a crash.The EPAS system was manufactured by TRW Automotive for Ford and was designated as Generation I.These units were first produced and put into vehicle production in July 2008 beginning with the model year (MY) 2010 Ford Fusion and Mercury Milan.The system is comprised of a mechanical steering rack-and-pinion gear with torque sensor, electric assist motor, motor position sensor and a power steering control module (PSCM). The PSCM is self-monitoring and designed to detect faults within the system and can store diagnostic trouble codes (DTCs) if a problem is detected.There are 29 potential DTCs the system can detect.Many of these allow the system to go into reduced-assist steering mode by using the default vehicle speed signal should the live speed signal be lost, if voltage to EPAS system falls below 10.7 or goes above 17 volts, the temperature at the PSCM goes above 105C (221F), or if high friction is detected.Some DTCs will cause the system to go into manual steering mode (no assist). On July 1, 2015, Ford filed a Defect Information Report (DIR) identifying a safety related defect in TRW GEN I EPAS systems installed in some of the subject vehicles (NHTSA Recall 15V-340, Ford No. 15S18).The DIR indicated that intermittent electrical connections caused by quality issues associated with conformal coat contamination and ribbon cable pin misalignment within the steering gear motor may lead to a loss of the motor position sensor signal, resulting in a sudden loss of power assist while driving.The recall covers approximately 393,623 vehicles built from September 2010 through February 2012:2011-12 Fusion built SEP 2010 - FEB 2012; 2011-12 Lincoln MKZ built SEP 2010 - FEB 2012; 2011 Milan built SEP 2010 - DEC 2010; 2011-13 Taurus built SEP 2010 - FEB 2012; 2011-13 Flex with 3.5L GTDI engine built SEP 2010 - FEB 2012; and 2011-13 MKS, MKT with 3.5L GTDI engine built SEP 2010 - FEB 2012.The repair consists of updating the PSCM software to prevent a loss of steering assist while driving. The revised software will provide audible and visual warnings to the driver. If one or more of the following DTCs are stored, C1B00-62, C200B-2F, C200B-61, C200B-62, C200C-2F, C200D-49, U0300-00, U2011-49, U2011-61, U3000-46, U3000-49, U3000-61, U3000-72, U3000-96, P07AE-09, the dealer will replace the EPAS system at no charge to the owner.ODI's analysis of failure data for this PE identified a total of 2,584 complaints to ODI and Ford and 9,967 Ford warranty claims related to the alleged defect.The recalled vehicles account for 1,634 of the complaints and 7,311 of the warranty claims.ODI's analysis identified 40 complaints alleging crashes that may be related to loss of steering assist while driving, 20 of which involved vehicles included in Ford's recall.The information available for the alleged crashes were not sufficient to assess specific causes of the incidents or to verify EPAS malfunctions in each case.Most of the crashes were low-speed impacts with curbs or roadside objects resulting in wheel or minor body damage.None of the injury claims indicated medical attention was required.In addition, statistical modeling of the failure data by NHTSA's National Center for Statistics and Analysis projected 10-year failur

On February 21, 2013, the Office of Defects Investigations (ODI) opened Preliminary Evaluation PE13-003 to investigate allegations of electronic throttle body (ETB) failures resulting in sudden reduction of engine power in model year (MY) 2009-2013 Ford Escape, Fusion, Mariner and Milan vehicles. During this investigation, Ford identified a condition in subject vehicles equipped with 2.5L and 3.0L engines that may result in a sudden reduction of engine power.According to Ford, the ETB internal motor contacts may develop a high resistance material buildup condition on the commutator, resulting in intermittent electrical connectivity and reduced engine power. When this condition occurs, the Malfunction Indicator Lamp (MIL) or Wrench light will illuminate and the vehicle may enter a limited limp home mode.Ford?s trade name for the feature is Failure Mode Effects Management (FMEM) mode.In this mode, engine power and vehicle speed are reduced, while full function of the power steering, power braking, lighting, and climate control systems are maintained.ODI?s complaint analysis indicate that the predominant failure mode involved reduced motive power associated with the limited limp home mode with engine speeds limited to approximately 900 RPM. Analysis of warranty claims provided by Ford identified 59,807 claims related to ETB replacements and approximately 50 percent of claims are associated with diagnostic trouble codes (DTC) P2111, Throttle Body Stuck Open, and P2112, Throttle Body Stuck Closed.Ford described several factors where the ETB motor may fail resulting in DTCs P2111 or P2112 but the failure is not an existing stuck open or closed ETB valve position.According to Ford, the ETB control strategy provides the driver with three FMEM modes that allow varying degrees of vehicle mobility depending on the severity of the fault detected.DTCs associated with stuck open or closed throttle valves are designated the highest failure severity resulting in engine speeds limited to high idle corresponding to the limited limp home mode.Vehicles are not likely to unexpectedly stall as a result of this condition, but drivers may characterize the reduced functionality as a stall, even though their vehicle may still has motive capability.Other FMEM limp modes may result in reduced engine performance but will maintain vehicle speed above 20mph. During this investigation, Ford and its suppliers, Delphi and Igarashi, updated the powertrain control module (PCM) software to include a throttle body motor cleaning cycle during key-on and modified the ETB internal motor components design, surface finish and material composition to improve durability. Additionally, Ford developed a remedy procedure and issued a special Customer Satisfaction Program (CSP) 13N03 extending the ETB warranty coverage and instructing dealers to update the powertrain calibration to improve vehicle performance in the event that intermittent electrical connectivity of the throttle body motor contacts occurs. The program extends the coverage for up to 10 years of service or 150,000 miles from the warranty start date of the vehicle, all vehicles are eligible for the program through January 31, 2015 regardless of mileage.Owners of the affected vehicles will be contacted by mail to take their vehicle to a Ford dealer who will reprogram the PCM to the latest calibration. The bulletin was sent to dealers on January 17, 2014 and the owner letter mailing began on January 27, 2014. See the investigative file for copies of Ford's bulletin and owner letter. This preliminary evaluation is closed. The closing of this investigation does not constitute a finding that

On May 27, 2014, Ford Motor Company submitted recall 14E-028 (Ford recall #14S07) to correct a safety-related problem with certain driver's side Ford optional all-weather floor mats sold for use in model year 2006 through 2011 model year Ford Fusion, Mercury Milan, Lincoln Zephyr, and Lincoln MKZ vehicles built at Hermosillo Assembly Plant (HAP) from November 9, 2007, to October 31 ,2010.NHTSA testing determined that the original accessory all-weather mat with a single retention clip (Figure 1), may interfere with accelerator pedal return to idle with the mat retained by the clip and rotated clockwise.Both the single- and double-clip (Figure 2) all-weather floor mats may interfere with the accelerator pedal return to idle when the mats are not secured by the retention clip(s).Testing showed that this can occur if the mats are moved forward from the clipped position approximately two inches into a position in which the rear edge of the mats will abut the retention clip(s) when installed singly and align with the clip(s) when stacked on another floor mat.The pedal interference incidents reviewed by the Office of Defects Investigation (ODI) include 1 crash and 9 incidents with allegations of brake friction materials smoking and/or requiring repair for heat related damage.The crash incident occurred after the parking brake was applied at speed, resulting in loss-of-control vehicle yaw event caused by lock-up of the rear tires.The spin-out resulted in a side impact collision with an oncoming vehicle in an opposing lane of traffic. For the 29 incidents with sufficient information available to make an assessment; 23 (79%) were controlled by the driver either shifting to neutral, turning the engine off, or both; 4 (14%) were ended by the driver either kicking the pedal free (2) or pulling the mat away from the pedal (2); and 2 (7%) were ended by the pedal freeing itself from the mat with no apparent driver action.None of the drivers who reacted to the incident by shifting to neutral or turning the engine off reported any difficulties with either action.The subject mats were sold by Ford and Lincoln dealers directly to customers as an optional accessory equipment item or, beginning in November 2007, the mats were also available as a factory installed accessory if ordered with a new vehicle.Ford estimates that approximately 82,579 affected driver's side all weather floor mats were sold worldwide; either over the counter through Ford dealerships or as original equipment.Owners that purchased the subject all-weather floor mats as a factory installed accessory with their new vehicle will be notified to return their all weather floor mats to their Ford or Lincoln Dealership in exchange for replacement mats.Owners of all other potentially affected vehicles will be notified that, if they have an affected Ford driver's side all weather floor mat, they should return their mats to the dealership in exchange for replacement mats.The VOQs associated with the closing of this investigation are: 10327597, 10332233, 10334211, 10335336, 10339330, 10348772 (and duplicate 10342572), 10372674, 10379562, 10415911, 10426255, 10434107, 10521053, 10554966.This investigation is hereby closed.

Gas tank leak, fuel fumes. Part of safety recall for fuel pressure regulator causing fuel tank rupture!!!

NHTSA ID

11754953

Incident

Jun 1, 2026

The contact owns a 2011 Mercury Milan. The contact stated there was an abnormal fuel odor coming from the vehicle and there was fuel underneath the vehicle. The contact researched and became aware of NHTSA Campaign Number: 15V793000 (Fuel System, Gasoline); however, the VIN was not included in the recall. The dealer was contacted and confirmed that the VIN was not included in the recall. The vehicle was not diagnosed or repaired. The vehicle was not repaired. The manufacturer was made aware of the issue and confirmed that the VIN was not under recall. The failure mileage was approximately 125,000.

NHTSA ID

11754479

Incident

May 3, 2026

Mileage

125,000 mi

On XXX My 2011 Milan, experienced a total loss of steering assist. Am original owner & have original invoice from former dealer (Vista Ford )dated XXX, Invoice #XXX shows the dealer only did a software patch under 15N01 because there were no error codes at the time. My physical defective steering gear was never replaced, and now suffers a total mechanical electrical failure. The manufacturers software recall patch failed to prevent the component from failing. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11750411

Incident

Apr 22, 2026

The contact owns a 2011 Mercury Milan. The contact stated while driving at an undisclosed speed, the electronic power steering failure warning light illuminated. Additionally, the steering wheel failed to turn in the intended direction. The contact's family member attached the ODS monitor to the vehicle, and fault codes: C1277 (Steering Wheel Angle Sensor), UL3000 (Power Steering Control Modular) and several other failure codes associated with the electronic power steering were retrieved. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The contact referenced an unknown recall; however, the VIN was not associated with a recall related to the failure. The dealer was not made aware of the failure. The manufacturer was not made aware of the failure. The failure mileage was approximately 91,430.

NHTSA ID

11743808

Incident

Jun 12, 2026

Mileage

91,430 mi

1) The electric power steering system failed. The dashboard displayed the message “Service Power Steering Now,” and the steering assist stopped working, making the steering extremely stiff. The vehicle also lost reverse gear, where the engine revs but the vehicle does not move when shifted into reverse. The vehicle is still in my possession and available for inspection upon request. 2) When the power steering assist failed, the steering wheel became extremely difficult to turn, which made the vehicle harder to control. This created a safety risk when attempting to turn or maneuver the vehicle in traffic or parking areas. Additionally, the inability to use reverse gear could create a hazardous situation if the driver cannot back out of traffic, parking spaces, or other areas. 3) The problem has not yet been inspected or confirmed by a dealership or independent service center. 4) No, the vehicle has not been inspected by the manufacturer, police, insurance representatives, or other parties. 5) The dashboard displayed the message “Service Power Steering Now,” and the steering assist stopped working. The problem appeared suddenly when the vehicle was started. The steering immediately became extremely stiff, and the warning message appeared at that time. This failure created a serious safety hazard because the steering assist stopped working without warning, making the vehicle extremely difficult to control. A sudden loss of steering assist can increase the risk of a crash, especially when turning, parking, or driving in traffic. I am concerned that other drivers could experience the same sudden steering failure. The vehicle displayed the message “Service Power Steering Now,” and the steering immediately became extremely stiff. The vehicle is currently undriveable in reverse and difficult to steer safely.

NHTSA ID

11722674

Incident

Jan 12, 2026

on 10/27/25 my son was driving car (2011 Mercury Milan) and light came on dash and car suddenly lost all power steering. Luckily car was able to be driven to side of the road when steering went out. I went to the Ford recalls website and it indicated "Epas steering efforts" was on the website as requiring free service. This recall is specifically for loss of power steering in car. Electronic Power Assisted Steering (EPAS) systems provide variable steering assistance but can experience issues leading to increased steering effort and loss of control. Upon checking with dealer, this was to be fixed under safety recall bulletin 15S18. This was initially repaired in 2015 under that recall bulletin. This did not fix the issue as the car requires a power steering gear replacement for same issue. Warranties on this recall are not being honored and this is deceptive as the final repair did not correct the problem. Federal law dicates warrenties do not expire on safety recalls. Upon checking the ford recall website, Ford is now indicating it can be fixed under a "Customer Satisfaction Program" to cover the original safety recall which has already expired. Now I am faced with almost a $3k repair on a safety recall which was never fixed and not being honored by Ford.

NHTSA ID

11696096

Incident

Oct 27, 2025

Passenger side brake light assembly failed June 2025. I found it our at an oil change inspection. Ford discontinued manufacturing this LED brake light assembly, so it is difficult to replace this safety critical part. The part number is 9N7Z 13404 A.

NHTSA ID

11675692

Incident

Jun 30, 2025

The contact owns a 2011 Mercury Milan. The contact stated that while the vehicle was at the dealer for servicing, the contact was informed that the electronic brake control module had failed. The contact was informed that the electronic brake control module needed to be replaced. The vehicle was being repaired. The manufacturer was made aware of the failure, but no assistance was provided. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was unknown.

NHTSA ID

11662594

Incident

May 8, 2025

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

All accessory stick-on keyless entry keypads come with a wallet card containing the master code. If the accessory keypad was factory installed, this card will be placed in the glove box and should be handed to the vehicles owner during initial delivery. Unlike the integrated (wired) factory keypad, the accessory keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool. If the wallet card for an accessory keypad is lost, follow these steps to recover the code. Dealer Key Code access is granted through the Dealer Program Enrollment System (DPES); dealership management can authorize users. The authorized user must go to FMCDealer.com > Parts and Service > Parts Product Line Information > Keys/Entry Devices > Aftermarket Keyless Entry Keypad Code Access. Follow the instructions on the screen to obtain the master code for the accessory keypad.

When performing any transmission fluid change or topoff involving Motorcraft® Premium ATF, MERCON® V has replaced all versions of Motorcraft® Premium ATF and can be used going forward. Mixing Motorcraft® Premium ATF and MERCON® V in the same transmission is acceptable. After 31-Jan-2024, Motorcraft® Premium ATF will no longer be manufactured and will only be available until inventory depletes.

Certain 2005-2014 Mustang, 2005-2006 GT, 2004-2011 Ranger, 2006-2012 Fusion and MKZ/Zephyr, 2006-2011 Milan, and 2007-2010 Edge & MKX Vehicles Driver & Passenger Airbag Module Quality Control Inspection REASON FOR THIS SUPPLEMENT • Updated Ranger Technical Information to include images of a pass and fail airbag inflator inspection for 2007-2011 model years.

Some 2010-2012 Fusion/Milan and 2011-2012 MKZ vehicles equipped with a 2.5L or 3.0L engine and electronic power assist steering (EPAS), a remanufactured replacement steering gear (MU2Z-3V504-ARM) is available which is significantly less expensive than a new replacement gear. When conducting repairs that are customer pay, offer the customer a remanufactured gear when possible. This would include vehicles not included in field service action (FSA) 15N01 (built on or before 7-Sep-2010) or vehicles included in FSA 15N01 that have exceeded the 10 year/150,000 mile terms of the program.

Some 2010-2012 Fusion hybrid electric vehicles (HEV), 2010-2011 Milan HEV and 2011-2012 MKZ HEV vehicles may experience reduced electric vehicle operation and increased gasoline engine operation around 10 years of vehicle age and beyond. This may be due to software in the battery energy control module (BECM) and the powertrain control module (PCM). To correct the condition, follow the Service Procedure to reprogram the BECM and PCM.