Brake Master Cylinder problems of the 2007 Ford Fusion

In December of 2018 the vehicle hit a rough surface of road as I was stopping near an intersection. The brake pedal immediately went to the floor and I went into the intersection. Thankfully there were no cars passing through. Just after the incident the brakes firmed up and worked as normal. Car was brought to the dealership and no issues were found. I asked about technical service bulletins and was told there were none. Dealership thought the issue was a brief loss of vacuum in the booster. Told to keep driving the vehicle, and if it happens again they will replace the master cylinder. Now on 10/9/19 it has happened again. Vehicle went over a bump and the brakes went to the floor. Looking online, I quickly found a youtube video back in 2014 with a full explanation on how the hcu is malfunctioning on some of these cars. After the abs event is over, the abs valve is sticking and not reclosing resulting in the soft pedal. Yet not long after, the pedal firms up and the brakes work as normal. It looks like there are quite a few people experiencing this. Please look into at least having a TSB put out. I would have replaced it last December if I had known, as this is a dangerous problem. My daughter was driving this time and I'm just thankful she was in a situation where she had enough room to stop. Please, please issue the TSB now. The car should be recalled as it's unsafe, but at least a TSB gives the owner/dealer the information needed to get the car fixed. Have record of visit to dealership in 2018 if needed. It shows that they were concerned about the hoses to the booster. Nothing about the hydraulic control unit.

I purchased the car new and have never had any brake issues. Yesterday driving on compact snow and ice at about 25 mph the anti-lock brake system engaged while slowing to start a turn. The brake pedal went almost to the floor before the abs engaged a second time. At this point I was already passed the intersection. Since this happened the brake pedal is very spongy and will travel almost to the floor before any braking occurs. A quick search of the internet shows this is a common issue with this make and model. Information is not clear what the issue is. Some report the master cylinder others state the abs control unit is to blame. There are many complaints of several service calls required and many $$$ to correct the problem.

Any time the abs system engages, break pressure is lost for extended periods of time, resulting in longer stopping distances. Usually the only way to get break pressure back is to turn the car off, let it sit, and pump the breaks hard several times before pressure is regained, sometimes not for several days. I have not yet been in an accident due to this but feel it is only a matter of time. It first occurred last year around this time when my car was around 116000 miles. It has occurred 2 more times since then including today. The master cylinder was replaced in August 2018 with no change in the problem. After extensive research and ruling out other possibilities, I believe the problem is due to the abs control module. I know there is research into this already, so I am adding my car to the list of affected vehicles to ensure something is done about this problem.

Brake pedal goes to the floor, and is undrivable due to safety issues. This problem has been going on for months with this vehicle, we have spent several thousand dollars, numerous parts for the abs brakes and oil leaks continually coming from the master cylinder. Problem never fixed, several mechanics could not figure out after replacing everything with the brake line and still brake goes to the floor. Brakes bled numerous times and nothing is different, replaced several parts and no improvement (hcu, brake booster, master cylinder, both rear brake calipers). Problems still persist. Very upset, this car is making us broke and still no recall!!?? same problem every day with the car, unable to safely drive it, for several months now, not just a specific date, but months-long problems with this car, we have a child with autism who needs to get to appointments and unable to drive him in this unsafe car. Also airbag is a safety hazard, was officially recalled, but no fix provided its been over 2 years since we were notified. These are serious safety risks.

After the abs engaged on the car on some ice (going approximately 20mph) the brake pedal sank nearly to the floor. Now I have no abs and the pedal sinks to about 2 inches above the floor before braking starts. I have had the lines and master cylinder looked at and they were fine. The dealer believes it is the abs pump that has a stuck valve. Apparently this is not uncommon and needs to be a recall not just an expensive repair bill for something that could kill people.

My problem is exactly as described in the open investigation NHTSA action number pe16017 called "extended braking distance". After engaging the abs due to icy and snowy conditions, my brake pedal became very "soft" and almost goes to the floor. The typical braking characteristics are changed dramatically, much greater force and distance are required to stop the car. This is very repeatable. Pumpint the brakes did not immediately help, but eventually the pedal did come back to the normal position. During the summer of 2017 I must have had the same problem without realizing it, the shop replaced my master cylinder but as of yesterday it's obvious changing the master cylinder did not help. I see this as a major safety issue, I will not let my daughter drive this car again until this is fixed.

On October 20, 2017 my elderly mother had traveled about 150 miles out of town. When traveling a two lane road a funeral procession was coming the opposite direction. She had pull the car half way off the road with one side off the road and the other on the road. When everyone started to go again the car in front of her came to a sudden stop. When my mother tried to stop she had no brakes. She tried to leave the road to avoid hitting the car in front of her but she ended up hitting the right corner of the car. . Thankfully my brother-in-law was behind her. He drove the Ford Fusion 150 miles using the emergency brakes for stopping her car. It was mostly interstate miles to get her home. If the brakes had not failed until she was on the interstate this could have been a fatal incident. Her 2007 Ford Fusion has 85,000 miles. She loved the car because it handles and rides so well even though the dash is buckling and coming apart. Now she is afraid of it. Her mechanic replaced the master cylinder which did not correct the problem. The car was taken to another mechanic who replaced the abs hydraulic control unit which corrected the issue. This is a rare part to fail and it is a real issue.

Tl the contact owns a 2007 Ford Fusion. The contact stated that the brake pedal traveled all the way to the floorboard in order to slow down or stop the vehicle. The contact stated that the abs pump malfunctioned and allowed the brake pedal to go to the floorboard. The dealer (pallotta Ford Lincoln, 4199 cleveland rd, wooster, OH 44691, (330) 345-6600) performed several repairs from bleeding the brakes to replacing the master cylinder; however, the failure recurred. The manufacturer was not contacted. The failure mileage was 90,000. The VIN was unknown.

The contact owns a 2007 Ford Fusion. While driving 10 mph, the brake pedal was depressed, but failed to respond. The brake pedal traveled to the floorboard without warning. The vehicle was taken to three independent mechanics, but the failure persisted. The vehicle was previously taken to norm reeves Ford superstore (located at 18900 studebaker rd, cerritos, CA 90703) where it was diagnosed that the brakes and master cylinder needed to be replaced. The vehicle was repaired, but the failure recurred. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failures. The failure mileage was 159,350.

I took my car into the dealer to have my brakes checked. I was told I needed new brakes and rotors, after replacing brakes and rear rotors drove the car out , less than a quarter of a mile on the way home brake paddle went down to the floor. Return to the dealer was suggested I need a master cylinder , the master cylinder was replaced was told that was not the problem. No one knew exactly what it was for two days, I was called and inform it was abs valve module. Ford dealer had to order valve module one week later still waiting. Don't understand why there is no recall. (many complaints).

Brakes are very soft after going over a rough patch in the road and tried to brake to control vehicle. Brakes went almost to the floor and felt like there was no control. Since then, brakes will feel like they have pressure but when I have to apply brakes the pedal goes down to the floor. I have had 2 master cylinders replaced and that does not solve the problem.

When backing out of a parking spot I depressed the brake pedal and it went straight to the floor. The car did not stop. I put car immediately into park and then pumped brakes. Pressure seemed to return to the brakes so I proceeded to back out again, testing brakes consistently. Brakes seemed to respond but seemed "soft" still. I drove car to mechanic without incident, thinking the problem was the master cylinder. Mechanic informed me that the problem was not the master cylinder but rather the abs hydraulic control module and that he had seen this same problem with four other Ford vehicles, two of them Fusions. Mechanic stated that when he looked up the symptoms I reported to him in his "identifix/oem" database that this problem came up associated with a technical service bulletin from Ford, including the instructions for how to repair the problem. He could not find a recall notice for this problem, however. This appears to be a manufacturer's defect and I am perplexed as to why there is no recall. I will be contacting the Ford motor company to investigate further. My mechanic repaired the problem which cost just over $2000 and did include him taking the car to a Ford dealer to reset the abs and associate the repair with my VIN. Two days since repair and I have not had any brake problems.

While driving around 25 to 30 mph on wet roads in stop and go traffic, I was braking normally and my right front tire was over a man hole cover. The abs engaged and the pedal went to the floor. The brakes have never returned to a normal feel. I've had the master cylinder replaced and brakes bled on numerous occasions and was finally told that the abs valve module was stuck open. I was quoted over $1,000 by Ford dealership. Can't afford it so I've learned to live with a spongy brake pedal. I just pray I don't need to stop suddenly.

Either in 2008 or 2009, shortly after purchasing a brand new 2007 Ford Fusion, I was greeted with the first major issue of my brakes going out on me while driving. Find out this was due to a defective master cylinder. The engine light turned on within 3-4 years of having the vehicle, and was found to be related to the thermostat, the engine would always run towards the cool end, never going above 1/3 of the way to the halfway mark. That was fixed after years of failed attempt. And all the while, I never had a functioning air condition unit and would have to repair yearly, and then found to be related the car always running too cool. Over the past two years, I have had to replace the gasket twice, because oil would appear in places it should not (I always maintain my car by doing the oil changes, etc on time). This past Sunday, I was driving and going around 70 mph when my car started to decelerate to 65, then 60, then would not go past 40 so I pulled off the interstate and drove back home. Over the next couple of days I smelled burnt oil, and the same issue with oil being where it should be happened again. Mechanic is telling me it is done, and after researching, this is not something unique to just my car. This is dangerous and people have reported many horrifying stores on the same issue, with some people's Fusions combusting and stalling them on the highway. I did notify the Ford company today of all the safety issues and other issues related to my car, just so they have it documented on their end as well. I am appalled this car does not have recalls other than the one related to the airbags, which they can not fix yet, posing my passenger at risk.

When in motion, the brakes have to depressed further to the floor than when new. The master cylinder was changed out under warranty but the problem was still there.