2015 Ford Fusion Energi

The defect

Ford Motor Company (Ford) is recalling certain model year 2014-2015 Ford Fusion vehicles manufactured July 27, 2013, to October 31, 2014, 2015 Ford Fusion Hybrid vehicles manufactured February 24, 2014, to October 31, 2014, and 2015 Ford Fusion Energi vehicles manufactured July 14, 2014, to October 31, 2014. In the affected vehicles, the key may be able to be removed even while the transmission is not in Park. Thus, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 114, "Theft Protection and Rollaway Prevention."

The risk

If the key can be removed despite that the transmission is not in Park, a driver may think the vehicle is safety parked, when it is not, increasing the risk of a vehicle rollaway that could cause the vehicle to strike and injure the driver, other vehicle occupants, or bystanders.

The remedy

Ford will notify owners, and dealers will repair the vehicles, free of charge. The recall began on December 15, 2014. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 14C11.

Ford Motor Company · up to 56,479 vehicles across all model years covered

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.

Still open engineering analysis · opened September 17, 2021

the air bags

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

Closed recall query · opened December 19, 2019 · closed February 7, 2022 · led to recall 20V177000

the latches, locks and linkages, the body structure

In December 2019, the Office of Defects Investigation (ODI) opened this investigation based on 235 Vehicle Owner Questionnaires (VOQs) alleging doors failed to latch when closed, and/or inadvertently opened while driving, on model year (MY) 2012-2014 Ford Fiesta, and 2013-2014 Fusion and Lincoln MKZ. Some VOQs reported the failure occurred after the latch had been remedied under a prior recall which involved fracture of the latch pawl spring tab due to thermally induced cyclic fatigue. Other VOQs alleged a similar failure in vehicles not previously recalled. A latch with a fractured pawl spring tab typically results in a ?door will not close? condition, however in certain somewhat rare circumstances, may result in the door coming open while driving. In response to ODI?s investigation, Ford has announced three field actions, as discussed below.On March 23, 2020, Ford submitted Safety Recall 20V-177 (Ford 20S15), a regional recall campaign to address door latch failures in vehicles not previously recalled under Safety Recalls 15V-246, 16V-643 and 17V-210. The recall affects vehicles currently or ever registered in certain high ambient temperature states (see 20V-177 for affected states). As a remedy, Ford will replace all four door latches free of charge.On August 24, 2020, Ford issued a non-safety regional field action (Ford 20R01) to address door latch failures on the same model/MY vehicles not covered under 20V-177 (i.e., not currently/ever registered in affected states). According to Ford, spring tab failure rates for vehicles covered by this action are about half that of the 20V-177 vehicles. Under this action, dealers will replace all door latches, free of charge, if either; a) the vehicle exhibits a related latch concern, or b) if the vehicle owner expresses a concern about the latches in their vehicles. Details can be found under NHTSA TSB No. 10190990, a copy of which is available in this investigative file available at NHTSA.gov.On June 8, 2020, Ford submitted Safety Recall 20V-331 (Ford 20S30) addressing vehicles previously remedied under NHTSA Recalls 15V-246, 16V-643 and 17V-210, where the repair may not have been properly completed, specifically not all of the door latches were replaced, or replaced correctly. This recall involves an inspection of the latches, with the option for a consumer self-inspection; owners could view the date codes on their latches (and confirm child safety locks are present on the rear doors) and then submit the information to Ford?s mobile app or website. A dealership inspection option was also available. Any vehicle found to have unreplaced defective latches requires the replacement of all door latches as directed by Ford.Regarding the 4,494 reports cited above, 1,485 involve scope-related failures (with 13% alleging door opening), and the remaining 3,009 reports involving remedy concerns (with 18% alleging door opening - note ODI was unable to verify the allegations of door opening). The three ODI injuries were all relatively minor. Ford?s reported injury incidences include one (unconfirmed) report of an ejection, three minor injuries with the others involving undisclosed injuries. Ford?s crashes involved two (unconfirmed) crashes alleging the incident door contacted another vehicle and three involving doors striking other property.The recalled vehicles include MY 2011-2015 Ford Fiesta, 2013-2016 Ford Fusion and Lincoln MKZ, 2015 Ford Mustang and Lincoln MKC, 2013-2015 Ford Escape and Ford C-MAX, 2012-2015 Ford Focus and 2014-2016 Ford Transit Connect.Ford's actions address ODI's concerns at this time. ODI will take further action if warranted by new information. The reference (OD

crash · 300 miles

I PARKED MY CAR, TURNED OFF THE PUSH BUTTON IGNITION, EXITED THE VEHICLE, LOCKED IT AND WALKED INTO STARBUCKS. HALFWAY INTO THE STORE I HEARD A CRASH SOUND, TURNED AND DIDN'T SEE MY CAR. IT HAD ROLLED FROM WHERE I PARKED IT ACROSS A PARKING LOT AND HIT A PARKED VEHICLE. IT EASILY COULD HAVE HIT AND HURT OR EVEN KILLED A PEDESTRIAN. WHEN I GOT INTO MY CAR I NOTICED I HAD INADVERTENTLY LEFT IT IN DRIVE. I TAKE RESPONSIBILITY FOR NOT PUTTING THE CAR IN PARK BUT I FIND IT DISCONCERTING AND DANGEROUS THAT THE CAR PROVIDES NO WARNING WHEN THAT IS DONE. HAD I LEFT THE CAR ON IT WOULD HAVE HONKED WHEN I EXITED THE VEHICLE. HAD I LEFT THE CAR IN DRIVE IN MY HONDA I WOULD NOT HAVE BEEN ABLE TO REMOVE …

NHTSA complaint 10713252, quoted in part. Filed by an owner and not verified by NHTSA or by us.

towed · 100,070 miles

The contact owns a 2015 Ford Fusion Energi. The contact stated while driving approximately 45-60 MPH, the vehicle started making an abnormally loud humming sound while releasing the accelerator pedal. The contact stated that upon depressing the accelerator pedal, the vehicle hesitated and jerked backward several times. The contact was able to continue driving; however, the failure reoccurred increasingly while driving the following day. The warning message "Engine coolant temperature - Pull Over As Soon As Possible" was displayed. The contact veered to the side of the road. The vehicle was towed to the local dealer where the failure was diagnosed as a transmission failure. The dealer …

NHTSA complaint 11470278, quoted in part. Filed by an owner and not verified by NHTSA or by us.

towed · 150,000 miles

The contact owns a 2015 Ford Fusion. The contact stated while driving approximately 55 MPH, the vehicle lost motive power. The contact stated that upon inspection, an oil leak was found. The vehicle was towed to an independent mechanic; however, the vehicle was not diagnosed or repaired. The vehicle was towed to a local dealer where it was diagnosed and determined that the engine needed to be replaced due to several holes and cracks being found on the engine block. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 150,000.

NHTSA complaint 11617448. Filed by an owner and not verified by NHTSA or by us.

towed · 100,008 miles

The contact owns a 2015 Ford Fusion Energi. The contact stated while driving at various speeds, the steering wheel became difficult to turn to the left or the right. The contact stated that the ABS and traction control warning lights were illuminated. The vehicle was towed to a local dealer where it was diagnosed and determined that the electrical rack and pinion needed to be replaced and recalibrated. In addition, the contact linked the failure to NHTSA Campaign Number: 15V340000 (Steering); however, the VIN was not included. The vehicle was not repaired due to costs. The manufacturer was made aware of the failure. The failure mileage was approximately 100,008.

NHTSA complaint 11660403. Filed by an owner and not verified by NHTSA or by us.

96,000 miles

The contact owns a 2015 Ford Fusion Energi. The contact stated that the engine control module failed to shutoff the vehicle causing the battery to drain. The contact was then unable to start the vehicle. The failure happened several times over a two-year period. The contact stated that to restart the vehicle he would break into the vehicle through the trunk to get to the battery and jumpstart the vehicle. The contact had taken the vehicle to the dealer and was informed that there was no recall associated with the VIN and that there were no known issues. The contact stated that the manufacturer knew about the issue but decided not to issue a recall. The manufacturer was made aware of the …

NHTSA complaint 11443137, quoted in part. Filed by an owner and not verified by NHTSA or by us.

50,000 miles

IF I CRANK THE CAR SOON AFTER CUTTING IT OFF, (WHILE IT'S STILL WARM) ENGINE SPUTTERS THEN QUITS, AS IF IT ISN'T GETTING ENOUGH FUEL. SO WHEN GETTING GAS, I HAVE TO HOLD DOWN THE GAS PEDAL OR ENGINE QUITS. AS SOON AS I START PUMPING, THE ENGINE STARTS CHOKING. I CAN'T TURN OFF THE IGNITION WHILE PUMPING GAS BECAUSE IT WON'T STAY CRANKED ONCE I TRY TO DRIVE AWAY UNLESS I REV THE RPM'S UP REALLY HIGH FOR A PERIOD OF TIME. I'VE HAD IT LOOKED AT SEVERAL TIMES AND NO ONE CAN FIGURE OUT WHAT'S WRONG. THIS HAS BEEN AN ONGOING PROBLEM FOR OVER A YEAR. AND NOW WHITE SMOKE BILLOWS OUT OF THE TAIL PIPE WHEN IT'S CRANKED. SECOND PROBLEM....ELECTRICAL. SOME OF THE STEERING WHEEL BUTTONS, SUCH AS CRUISE …

NHTSA complaint 11162795, quoted in part. Filed by an owner and not verified by NHTSA or by us.