Three problems related to brake drum wheel cylinder have been reported for the 2010 Ford Fusion. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2010 Ford Fusion based on all problems reported for the 2010 Fusion.
The master brake cylinder/hydraulic pump and control module became faulty and failed at roughly 43000 miles. My mechanic informed me that this is typically a part that should not fail with this few miles and was suspicious when he called the local Ford dealer and they had over 10 in stock. He informed me that in his 20+ years he has not seen dealers have that many high dollar parts in stock and advised I file a claim with Ford motor. I did file a claim with Ford motor but was advised they were not aware of any wider issues with the master brake cylinder/hydraulic pump and control module on my make and model year. Ford motor case numbers- cas-8423129 and cas-8428833 I noticed that my master break cylinder failed when I started my car one morning and the break pedal went all the way to the floor. I had my car repaired at my local Ford dealer, covert Ford in austin, TX.
The contact owns a 2010 Ford Fusion. While driving various speeds and depressing the brake pedal to stop the vehicle, the brake pedal traveled to the floor of the vehicle. The stopping distance increased. The vehicle was taken to the dealer where it was diagnosed that the brake cylinder failed and needed to be replaced. The vehicle was repaired, but the failure recurred. The manufacturer was notified. The approximate failure mileage was 52,046.
As has been documented dozens of times on several websites, I too, like others, experienced total brake failure by my 2010 Ford Fusion. Like other documented complaints, I too found that, in a situation where sudden braking is required, I experienced total brake failure. Normal braking on roads and streets has not resulted in brake failure for me; however, in the one situation where sudden braking was required, my 2010 Ford Fusion -- fully serviced solely and regularly (each ~5000 miles) by Ford service technicians since its purchase new in 2009, now at 81,000 miles -- I experienced: 1) no braking, 2) no slowing down, 3) no front-end-of-the-vehicle-diving-down when brakes were applied (inertia), 4) no skid marks on the dry pavement -- just utter and complete failure by the braking system in my 2010 Ford Fusion as I drove around a building (15-20 mph) and suddenly saw, braked, & hit a stationary pick-up truck on the road. At the scene of the crash, upon attaching the 2010 Ford Fusion with chains, the tow truck driver mentioned that he saw brake failure. Following the crash, I had a mechanic go with me to the salvage yard where my auto insurance company had the 2010 Ford Fusion towed; the mechanic did a 15-20 minute inspection, with a salvage yard employee watching, which indicated that, yes, indeed, the brakes had failed before there was the collision (the area of collision on the front right destroyed the abs area). While there did not appear to be any deficiencies in the brake lines, which were checked regularly by the Ford service technicians, there was failure involving the master brake cylinder at the time of sudden braking. Rather than being dry or dusty, the mbc was covered completely in goo. Not a sign of safety or properly-working parts. Despite these truths, my insurance company tells me I have to pay, since there has been no recall issued. Why not yet???.