2011 Ford Fusion Hybrid

Closed defect petition · opened January 27, 2023 · closed August 7, 2023 · led to recall 22V063000

the electrical system

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

Closed preliminary evaluation · opened October 2, 2014 · closed September 10, 2015 · led to recall 15V340000

the steering

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

Closed engineering analysis · opened December 12, 2012 · closed June 12, 2014 · led to recall 14E028000

vehicle speed control

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.

towed · 58,900 miles

TL* THE CONTACT OWNS A 2011 FORD FUSION HYBRID. WHEN THE VEHICLE WAS STARTED, "STEERING ASSIST FAULT" APPEARED ON THE SCREEN. IN ADDITION, THE ELECTRONIC STABILITY CONTROL WARNING INDICATOR STARTED TO FLASH. THE VEHICLE WAS TOWED TO LARRY H MILLER FORD (11595 6TH AVE, LAKEWOOD, CO 80215) WHERE IT WAS DIAGNOSED THAT THE ELECTRONIC VACUUM PUMP NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 58,900.

NHTSA complaint 11205579. Filed by an owner and not verified by NHTSA or by us.

80,000 miles

The contact owns a 2011 Ford Fusion Hybrid. The contact stated while driving at an undisclosed speed, the steering wheel seized, with the steering assist failure message displayed. The contact stated that the steering wheel became difficult to turn. The vehicle was able to restart. The vehicle was taken to the dealer where it was diagnosed, and it was determined that the steering assembly had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance. The approximate failure mileage was 80,000.

NHTSA complaint 11626397. Filed by an owner and not verified by NHTSA or by us.

142,000 miles

The contact owns a 2011 Ford Fusion Hybrid. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic to be diagnosed. The contact was informed that the powertrain control module had failed and needed to be replaced. The vehicle was not repaired. The vehicle was taken to the dealer but was not diagnosed or repaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance. The approximate failure mileage was 142,000.

NHTSA complaint 11623417. Filed by an owner and not verified by NHTSA or by us.

170,000 miles

The contact owns a 2011 Ford Fusion Hybrid. The contact stated that upon starting the vehicle, the steering wheel became inoperable. The contact drove the vehicle without power steering functionality downhill. The service power steering immediately message was displayed. The contact stated that the failure was related to NHTSA Campaign Number: 15V340000 (Steering). The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 170,000.

NHTSA complaint 11609441. Filed by an owner and not verified by NHTSA or by us.

towed · 77,625 miles

The contact owns a 2011 Ford Fusion Hybrid. The contact stated while driving at an undisclosed speed, the steering wheel was difficult to turn and failed to function as needed. Additionally, several unknown warning lights were illuminated. The vehicle was taken to the dealer where it was diagnosed with steering rack failure. The contact was informed that the steering rack needed to be replaced. The vehicle was being repaired. The contact stated that the steering rack had been replaced five times starting in 2023. In addition, the contact stated that on several of the failures, the vehicle was undriveable and was towed to the dealer. The manufacturer was not made aware of the failure. The …

NHTSA complaint 11599213, quoted in part. Filed by an owner and not verified by NHTSA or by us.

towed · 130,000 miles

The contact owns a 2011 Ford Fusion Hybrid. The contact stated while driving 10-15 MPH and depressing the brake pedal several times, the vehicle failed to respond. There was no warning light illuminated. The contact drove in a circle and slammed on the brakes, and the vehicle responded. The vehicle was towed to an independent mechanic, where it was diagnosed that the failure could be related to the ABS module. The mechanic informed the contact that it was a common failure and referred the contact to the dealer for assistance. The vehicle was driven to the dealer and the contact was informed that the ABS warning light was illuminated. The vehicle was diagnosed with internal electronic …

NHTSA complaint 11587720, quoted in part. Filed by an owner and not verified by NHTSA or by us.

towed · 150,000 miles

The contact owns a 2011 Ford Fusion Hybrid. The contact stated while driving at an undisclosed speed, she became aware that the electronic power steering was not functioning properly. The contact stated that the "Service Power Steering" message was displayed. The vehicle was towed to an independent mechanic, who diagnosed a failure with the power steering control module. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 15V340000 (Steering) but the VIN was not included. The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was 150,000.

NHTSA complaint 11558432. Filed by an owner and not verified by NHTSA or by us.