Brake Master Cylinder problems of the 2009 Ford Fusion - part 1

On my 2009 Ford Fusion: the brakes started getting softer and taking longer to stop the vehicle, on the highway or city streets. I have pulled and tested the master cylinder the brakes are fine and are not low, the brakes have been bled, went through 2 large bottles of dot 3 fluid, calipers tested, but the brakes are still soft and will not catch until almost to the floor. I went to a Ford dealership because they eluded to the idea that there was a fix for the recall regarding the abs valve, I got there and they said there was not a fix and the recall issue has not caused any crashes and it would not cause my brakes to go soft. I corrected him and said it has caused crashes and that is exactly what happens to the brakes. I cannot order a new abs module, no parts companies have them. So the car barely stops and still no fix available for this recall issue.

Brakes go nearly to the floor when pressing brake pedal before engaging and stopping vehicle. Spongy. Replaced master cylinder with new, no help. Replaced abs hydraulic unit with used unit, and no help, but suspect the replacement unit is faulty also. Vehicle does not stop well.

My brakes go out almost completely when there is the slightest bump that I might hit on the road. Firestone has replaced the brakes, brake fluid, and master cylinder and the brake pedal still goes to the floor. The research I did shows that the problem is the abs module. I've found hundreds of people in online forums with this problem. Why is there not a Ford recall with this problem?.

Have been dealing with a brake issue for a few months. Took it to a mechanic who replaced the brakes pads. After they were replaced, the brakes still felt off. I would have to push the brake pedal down all the way to the floor for it to stop completely. Took it to a second mechanic who then replaced the master cylinder. Still had the same issue. When I returned to the mechanic, he looked over the air and stated there was nothing else wrong with it. Finally I went to dunphy Ford where the greeter stayed he already knew what the problem was before I finished explaining the complete issue. He assured me it was the hcu (which of course was almost $1000 to replace) so I had it replaced. After picking up the car it felt fine for the first two days. The. The issue started happening again. When I returned the car to Ford, they told me it was the rear rotors. I asked how could they miss that when they replaced the hcu, there was no answer. The rotors were replaced. That night I went to pick up my car. After driving off, my brakes now made a very loud squealing sound and sort of clanking sound every time I hit a small bump on the road coming from the right side of my car. Well I checked every tire and found one of the lug nuts was loose on the front passenger side of my car. Called them and had he car & brakes looked over once again. This time they tightened the lug nuts and �buffed� the rotors. The brakes still make a pretty loud sound when I brake but no one can seem to figure out the issue. Not even Ford. I can send in invoices and receipts if needed.

Tl the contact owns a 2009 Ford Fusion. When the contact attempted to apply the brakes after driving over a bump in the road, the brake pedal traveled to the floorboard. There were no warning indicators illuminated. The vehicle was taken to dave sinclair Ford inc. (7466 s lindbergh blvd, st. Louis, mo 63125, (314) 892-2600) where it was diagnosed that the master cylinder needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and did not assist. The failure mileage was 62,500.

Brakes go to floor. No leaks, master cylinder is ok, rotors pads are new.

Tl the contact owns a 2009 Ford Fusion. While driving 25 mph, the brake pedal was depressed and took an extended amount of time to stop the vehicle. The contact stated that the brake pedal traveled to the floorboard. The vehicle was taken to an independent mechanic where it was diagnosed that the abs pump and brake master cylinder needed to be replaced and followed up by a brake fluid flush. The vehicle was not repaired. The dealer and manufacturer were not contacted. The approximate failure mileage was 144,000.

Brake pedal fell to the floor after abs initiated (skid on ice). Requires significant force to stop vehicle. Brake fluid is full and master cylinder is not compromised.

The brakes in the car seemed "squishy" or soft requiring that the driver push the brake pedal nearly through the floor to engage the brakes. I have taken it to multiple shops and had multiple repairs including but not limited to, 2 brand new master cylinders. Several near miss incidents have happened but luckily no accidents. I took the car in today to have the takata airbag recall completed and was told I needed a new hcu. It is my understanding that there have been multiple complaints regarding this make and model regarding faulty hcu parts.

After engaging the abs system on a gravel road, the brake pedal went soft. It now requires significant pumping and increased distance to stop the vehicle. The master cylinder was replaced, but this did not fix the problem. Research uncovered that this is a known problem/defect with this model year Fusion. I am wondering if there is any momentum towards a Ford recall on this abs issue. It is a significant safety hazard, and well documented.

Issue with brake pedal going all the way to the floor - with difficulty coming to a normal stop. There is a need to brake way ahead of the normal distance to avoid potential accident. Master cylinder was replaced, no lose of fluid, checked by multiple mechanics, and there isn't an obvious issue except possible faulty parts. Researching has indicated this has affected many other drivers in the same way. I noticed an investigation was created in April of 2018, but I don't see a resolution. There have been more than 25 accidents to date directly related to this issue. It would seem prudent and responsible to issue a recall to address the large scale issue.

Soft brake petal / brake petal goes to floor within 17 seconds resulting in compromised brakes and a safety hazard (all speeds and stopping situations). Seems to be a very common complaint / safety issue but still no recall or service bulletin from my understanding. I saw NHTSA is investigating, so I wanted to share I am also having issue and feel it is unsafe. Mechanic thought like most at first it was a bad master cylinder and replaced. Petal still soft so he bled brakes several times and was confident no air in system. I brought back car 3x over a year concerned the brakes feel 'abnormal/weird'. Each time brakes were re-bled and he agreed they felt unusual, he felt they were ok. My young daughter drives the car daily, so being concerned I researched and pressed dealer for info and found there is a known issue with a valve sticking in the anti-lock brake hydraulic valve unit resulting abnormal internal hydraulic fluid flow and gradual pressure loss. The price for a replacement valve body is an expensive $544 at Ford and 3-hours of labor to replace. My mechanic feels this is a recall worthy safety issue and needs reported. No idiot light or code notifies driver or mechanic failure has occured and he said antilock systems should not have such pressure failure with a part issue. Without recognition from Ford, the condition is misdiagnosed and results in mechanics thinking it is probably ok when it is not safe. My daughter has driven the car in this condition for about a year now while we try to resolve and we probably did an expensive, unneeded repair. It is disappointing to learn there hasn't been a recall or warning. An $800 repair for a most likely defective part is excessive (not to mention the $350 unneeded master cylinder repair. The temptation for many will be to 'live with it' due to high cost of repair or never know.

Very soft brakes. - the car kept experiencing soft brakes after the abs would engage or if the car hit a pot hole of solid bump in the road. Not all the times but fairly often. We replaced the master cylinder in 2016 and the brake pads recently as well. In Dec of 2017, I was going about 25mph while approaching the exit of our neighborhood. There was a small patch of ice & water. I was braking for a stop when the car crossed the patch. The abs engaged. From that moment on for about 2 weeks the brakes would go to the floor before they would slow the car to a stop. Then it cleared up. On Sunday April 22 around 1am, we were driving through a town on our way back from picking up our son. It had been raining steady for several hours. My husband was driving less than 35mph approaching a traffic light that had just turned yellow. He tried to stop for the light. The abs engaged but the car did not stop. The light turned red before we got to the intersection but the car was not stopping. We ran the red light. The car did finely slow down to an almost stop but we were already through the intersection. Luckily there were no other cars around at the time but from that moment on the brakes have been soft. After finishing our trip home about 300 plus miles and going to the store where we live about 5 miles, we are afraid of driving the car anymore. It takes too long to stop and if someone stopped quickly while in front of us or if something ran out in front of us while driving, we don't believe we could stop quickly enough; safely.

While approaching an intersection, brakes were applied for a red light which lost all hydraulic pressure after front right wheel went over a pothole. To fully stop the vehicle, the brake pedal had to be pushed fully to the floor. Subsequent driving showed virtually no return of hydraulic pressure in the brakes. This occurred within months of having brake pads, rotors, fluid, and master cylinder inspected by Ford-branded dealer.

On multiple occasions I have had difficulty with stopping the vehicle regardless of the weather conditions. I have had my brakes checked repeatedly and been informed that my pads, rotors, master cylinder are all in great condition. I have had the brakes bled, brake fluid change and it has not rectified the issue. On more than one occasion I have either ended up on the side of the highway or almost hit another vehicle trying to stop. There is no forewarning as to when this happens. The brake pad is extremely spongy and at times when being pushed goes nearly to the floor. This has happened on the street, on the highway, the worse and most scariest incident was driving highway 77-south through wv, going through the mountains. I have counted 13 incidents of this over the past year. There have been more incidents over the span of 3 years but on each previous occasion I was told that air gets in the brake line and to pump the brakes. This clearly has not elevated the issue. The most recent evaluation by a mechanic assured me that my brakes themselves were in good condition.

Initial experience was abs engaging while making a turn thru antiskid gravel. Pedal immediately went soft, luckily not on heavy traveled road. Returned home, disconnected battery, reconnected after a while, issue seemed to have resolved itself. Next incident was 12/9/17 during a snow event here in ne PA. When I crested a slight hill and applied the brakes to slow for stopped traffic. (high traveled road) abs engaged, pedal immediately went soft. I was unable to control the car with braking, so I steered off the road to the right shoulder area. To avoid striking a object head on, (cemetery headstone) I was able to steer back to the left, but then had to avoid a utility pole. I was concerned a) with electrical wires coming down, b) air bag deployment since vehicle is one affected by takata switches. I avoided the pole, but ended up striking a support guy wire. This resulted in over $3,000. 00 damage to front of vehicle, but luckily airbags did not deploy. However, had the guy wire not stopped me I would have slid back out into traffic, as I was on snow covered grassy surface. Vehicle not driven after that. Dealer looked at vehicle in January, no codes in computer. Flushed and refilled brake system, had normal braking. Recently went around same corner as initial entry, (early March) problem immediately recurred, pedal almost to floor. As with other posters, pumping pedal does restore some brake capability, but only for that instance. Pedal is soft again directly after. I have spent $2,000. 00 already, and dealer says either master cylinder or hcu, or both. Seems to be hcu based on other complaints. Car has 95,xxx miles. Nhtsa needs to get on Ford to address this issue pronto, before there is a death. I purchased this vehicle based on cr reports. I am not happy. It seems once they have your money, they don't care. Car not purchased new, had low mileage, one previous owner.

I was driving and needed to stop quickly on uneven pavement. When I pushed the brake pedal, it was almost like something slipped and the brakes would not catch. I then lost the pressure in my brakes and was unable to come to a complete stop. I was able to slow the car down and pump the brakes to get the pressure back. But it has not functioned the same since and the braking system is unreliable at best. I've since had brake pads, rotors, and the master cylinder replaced with not much improvement. I will be trying to replace the abs hcu unit. I really think this needs to be a recall at this point. I drive a maximum of 10 miles most days and am not hard on my vehicle. It should not break from braking on uneven pavement.

For the last few months I have had intermittent problems with my braking system. Many times, when I would apply the brakes as I was going over uneven surfaces or gravel, the abs system would engage and the brake pedal would lose pressure. During this time I would have to apply a much greater force to the pedal to get the car to stop. Almost every time this would happen, I would not stop where I was intending to, but would go by my intended target. Until today, this has not caused problems. However, today, I was traveling at a speed of approximately 25mph as I was going down a hill and approaching a turn. As I was applying the brakes the abs system engaged unexpectedly, the pedal lost all pressure and went straight to the floor, and the car was not slowing down at all. I lost control of the vehicle, went over a curb, hit an embankment and finally came to a stop. I had the vehicle looked at, immediately, by my local mechanic. He told me that the general braking system seemed to be in good working order (pads, rotors, calipers, hoses, pressure, master cylinder, etc. . . ) he mentioned that this model of vehicle had some problems with the abs systems and recommended that I take it to my local Ford dealer. I have an appointment with them this week. In the meantime, I researched the abs issue he mentioned and found the open investigation into exactly my problem. This is another complaint showing that this problem is very real and quite dangerous. Nhtsa action number: pe16017.

Driving in light snow approx. 20 mph, stopping at a stop sign pedal went to floor and remained soft, pumping pedal brought it up again slightly but stopping is very slow. After not moving it for a day, pedal came back up and seemed fine. Second time this has happened in 6 months. It is now in the repair shop as I feel it is unsafe to drive. Mechanics have said it is mechanical either master cylinder or abs valve but there is no test to determine what the problem is according to Ford mechanics. There are only 73000 miles on the car. Seems this happens when it is wet or snowing and it is random when it happens, however once the pedal goes to the floor it does not come back up to normal until after the car sits for a day. This is a very expensive repair and if it turns out to be the valve there is a 3 day wait to get the part, in the meantime I am forced to rent a car also. I have heard that Ford is well aware of this issue but is not addressing the situation or taking responsibility for poor design and engineering. In the meantime the consumer is forced to either pay for the repair or get rid of an unsafe car.

Issue happened 4 times in last year and a half. Slight skid twice on wet pavement, once on stone driveway, and once on wet metal sensor plate leading into toll booth. All 4 times were at low speed. Two times I was turning. Two times I was just slowing to a stop. Brake pedal went soft and braking distance increased. Soft pedal gradually improved over a period of weeks, but still felt softer than it should be and I questioned the reliability. The first time it happened, I took to a mechanic who couldn't find anything wrong. The last time I took to a Ford dealership, told them the symptoms, and asked them to check the hcu for the abs. They told me the master cylinder was shot and had to be replaced and they could only check the hcu afterwards, which turned out to be faulty. So they ended up replacing both the master cylinder and the hcu. The bill was $2000 but the brakes now feel like they are supposed to.

2009 Ford Fusion - brake system: I have been having trouble with my vehicle for over a year. When the anti-lock brake system (abs) engages while my car is in motion due to sudden stops, braking on wet surface, crossing uneven surface (railroad tracks) while braking, or maintaining speed while crossing a pothole my brakes become "spongy" immediately after. The brakes feel as if the brake pedal lost pressure requiring me to press my brake all the way to the floor. This has increased my stopping distance and has become a safety concern. These occurrences happened on a city street and/or highway and has happened going straight or turning. The speeds in which my abs has engaged occurred at or below the speed limit of the road I was on (I. E. 15 mph to 70 mph). At first, I would pump the brakes and my brakes would return to normal within an hour or so. It has gotten worse over the year or so and currently my brakes do not return to normal and are still in the "spongy" state. Last month I had my master cylinder replaced and I thought that had fixed the problem up until yesterday when my abs engaged again crossing train tracks while decelerating. My brakes are currently in the "spongy" state due to yesterdays event. I am uncertain to what the cause of the problem is but can speculate from online forums that it could be the hydraulic control unit. Please contact me if you need any additional information. I do not currently have my invoice from the master cylinder replacement with me but can obtain it if needed once I get home.

Once the abs mode is activated from a hard braking the front wheel locks up leaving no braking available until the Fusion is almost stopped. Once the vehicle has slowed significantly the locked wheel releases and brake function returns to normal. The dealership that sold the vehicle did replace the master cylinder but it made no difference once hard braking was applied. This situation gets worse during inclement weather allowing the front wheel to lock up much easier and quicker. It worries me that this is their only vehicle and they always have their 3 children with them.

Initially, on a wet city street at 45 mph, the brakes failed with the pedal going to the floor. Pumping the brake seemed to restore the brakes. Several weeks later, travelling at 35 mph on a dry city street, my brakes failed as I approached a yellow traffic light. With the brake pedal depressed to the floor, I travelled through the intersection on a red light. I took a back road to get back to my point of origin and was unable to stop for any of the stop signs. The master cylinder and the booster were replaced but did not solve the problem. After weeks of being checked out by a Ford dealer, the vehicle was returned to me but the brakes are still soft and feel unsafe. It sometimes feels like the car accelerates after I depressed the brake pedal before the braking kicks in. A longer stopping distance is required.

Takata recall. The brakes seem to not be fixable. I have replace brake pads, master cynlinder, flushed out break fluid, bled brake. Brake are still not working properly. If I hit a bump at a pretty good speed, the brakes get worse and then I have to push the pedal all the way to the floor and still doesn't really slow down. I have spent a lot of money on getting these brakes repaired and still not working properly. I hit on brakes to pull over and I hit a bump on the side of the road and brakes stopped working properly again. I don't know what else to do. I have had Ford dealership inspect brakes and they said I need to replace master cylinder. I replaced it and no change.

Have had 2 incidents of abs engagement followed by loss of brakes, where pedal went down to the floor. First time was in February of this year. Road conditions were slick and the car slid slightly. Abs was activated and then there was loss of brakes. Had the car towed to a local mechanic and the whole brake system was inspected. All that was found was some air in the lines and brake pressure came back. Rotors, pads, calipers, master cylinder were fine. Second incident happened August 5th while going on vacation. Was about an hour from home when I slowed down to go through a toll booth. Road was wet and I hit a slight bump going through the toll. After I got through the toll, brake pedal sunk to the floor! I then exited the turnpike and headed back home and drove it back an hour with no brake pressure. Fortunately it was early morning and traffic wasn't heavy. I got home, switched all of the luggage into my other car and I called a friend who works on cars and he said I could drop it off and he would look at it while we were on vacation. While he had it, the brake pressure came back. But again entire braking system was inspected and nothing wrong was found. There has to be a glitch in the abs. The first five years I had the car, nothing like this ever happened. Other on line postings I've read describe similar situations happening when the vehicle has 60,000 or more miles on it. My vehicle is at 60,000. Ford needs to look into this! does someone have to get seriously injured or killed before they take any action?.

The contact owns a 2009 Ford Fusion. While driving 45 mph, the brake pedal was depressed and traveled to the floorboard. There were no warning indicators illuminated. The vehicle was taken to kunes country Ford of antioch (104 IL-173, antioch, IL 60002, (847) 250-0238) to be diagnosed. The contact was informed that the brake master cylinder needed to be replaced. The brake master cylinder was replaced; however, the failure recurred. The vehicle was then re-diagnosed and the contact was informed that the hydraulic control unit needed to be replaced. The vehicle was not repaired a second time. The manufacturer was notified of the failures. The approximate failure mileage was 100,400.

I had to hit my brakes to avoid a collision while driving on a city street while it was raining. Ever since, the brake pedal has gone all the way to the floor with very little pressure. The first occurrence happened in June 2017 but has been a continous and very scary issue since then. I took my car to a Ford dealership where they originally told me the master cylinder needed to be replaced. The master cylinder was replaced but I was told that the brakes were still not working correctly. Upon further investigation by the dealership, I was told the hydraulic control unit would need to be replaced. The car is currently being serviced at a Ford dealership.

I have experience a soft brake pedal during/after going over a bump, and its occurs randomly and has happen to me a few times. I have had numerous components replaced and even after taking to the dealer and having the brake line go through a bleeding the issue did not resolve. . Read more...

While driving in my neighborhood I hit a rough spot in the road and my brake pedal went to the floor I could barely stop the car. I took the car to a local shop and they replaced the master cylinder and brake booster. Still no brakes, they replaced the abs module with a used unit a new one is 1300. 00 dollars and that fixed the problem 1168. 00 dollars later. I called Ford and if they could help me with the cost of this and they said it was not a recall. I will not be purchasing a Ford product in the future. The abs module in these cars are defective.

As stated in NHTSA action number: pe16017, my car is having the same issue of the brakes going to the floor and not being able to build brake pressure. I have fixed/replaced every brake component (calipers, brake booster, master cylinder) but have not replaced the abs control module. All research leads to this being the issue of the valves sticking open and causing not brake fluid pressure to build.

This is the second time we've had issues with the braking system on our 2009 Ford Fusion. The first occurrence was in August 2016, the second on November 30, 2016. This last time I took the vehicle to the local Ford dealer and had them do a thorough diagnostic check on the braking system. The dealership says there is nothing wrong with our brakes that they can document or replicate. However, the failure of the breaking system, temporarily, nearly caused an accident for my son this week. Back in August it was my wife that had the episode. In August she was driving on a wet blacktop four-lane divided highway and hit the breaks for a car slowing in front of her. Immediately she had almost no breaking function, with the pedal being extremely soft and going almost to the floor. This was not a case of pulsating abs action like normal. She was able to pump the brakes aggressively for a while and gradually get back enough breaking function to drive the car home. On inspection the brake reservoir was full. This week, the same thing happened on a perfectly dry concrete four-lane divided highway during a braking action when preparing to make a turn onto a side road. He nearly hit a brick sign at the college campus entrance. He pumped the brakes repeatedly and gradually had enough breaking function return that he could drive slowly to the parking lot. I took off work and drove down to meet him and tested the vehicle. The master cylinder was full to the normal level. There was no sign of leaking on any of the calipers or on the ground below. The brake pedal was still very soft but after pumping gradually returned to normal so that I could drive the vehicle home very slowly. We've now almost had two accidents when the brakes fail temporarily and without warning, then gradually return to normal operation. What is going on here? this is really scary and frustrating.

I purchased this used car on sept. 28, 2016. Five weeks later, on Nov. 4, I was nearing a red light on a city street and began to brake. Unexpectedly, the abs engaged and I found myself without any braking power. I had to push the brake pedal to the floor until the car eventually stopped approximately 12-15 feet later. If another car or a person had been in front of me, I would have hit them. I immediately contacted the Ford dealership where I bought the car (autonation Ford of white beat lake, minnesota), told them what happened and then drove my car slowly to the dealership where they kept it for four days. They replaced the master cylinder and I was led to believe that that was the end of the problem. The dealership claimed that they didn't know what else might have caused such a braking problem. Five weeks later, on Dec. 10, 2016, the same thing happened on another city street as I approached a red light except this time the abs engaged because the road was semi-slippery after a snowfall and I had to brake a bit harder. Again, the brakes didn't work properly and I had to press them to the floor. My car ended up sliding through the intersection (against a red light) before coming to a stop. Luckily, there wasn't any other traffic or obstacles in the intersection or I would have hit them as well. I did some research on the internet and discovered that there have been numerous similar complaints with Ford Fusion abs systems, including a number of complaints made to NHTSA. (there's also a video about the problem at youtube. ) I discovered that the problem is often misdiagnosed and that the cause if a faulty/defective abs hydraulic control unit needing to be replaced in a significant number of Fusions built within the last several years. These Ford Fusions with faulty abs need to be recalled before there are injuries and fatalities, if there haven't been already.

When pressing brake pedal at any speed the pedal goes all the way to the floor. When I took to dealer for repair they told me that the problem was due to master cylinder. I paid over $800 for repair but the problem persists. Now dealer is telling me it could be the abs. They are asking for an additional $1000 to fix. Help me? I am continuing to drive the car.

Brakes go to the floor at different speeds greatly increasing stopping distance and poses significant safety concerns. Brake hcu (hydrolic control unit) /abs system malfunction poses issues with bumps in the road, and braking while turning even at slow speeds. Brakes return to normal after being pumped and no other malfunctions with brake system (brake booster/master cylinder/brake pads, calipers, brake fluid) operating normal after ase dealership master mechanics can be identified. Occurs in city streets, driveway, parking lots.

I own a 2009 Ford Fusion sel with the 3. 0 engine. I have a problem with the brakes. The brake pedal is very sponge, I have replaced pads, calipers, and the master cylinder. This has not taken care of the problem, I have reviewed other information and it seems this is a very common problem. Ford has not done anything about it. I have researched more of this problem and the only thing left is the abs pump and motor. My research shows this has taken care of the problem, the cost to do this is approximately $1500. Plus labor cost. I have not had any close call accidents as some of the other complaints. This is and could be a accident waiting to happen. This problem occurs all the time while driving.