Three problems related to manifold/header/muffler/tail pipe 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.
2016 Ford Fusion. Consumer writes in regards to head gasket and exhaust manifold issues. The consumer stated the engine was replaced twice, the power steering and various sensors were replaced twice as well. The manufacturer was notified, but could not determine the failure.
Driving on a busy interstate highway when suddenly my car looses power and goes into limp mode. Absolutely no throttle response. Wrench light indicator came on. I pulled over to the side of the road and my car shuttered a bit as I slowed down. Turned the car off and waited a minute before restarting. Restarted sluggishly. Began driving again and no more than 5 minutes later, the same thing happened. This time the check engine light came on. Once again, turned car off, restarted and began driving again. Made it into a local brake/muffler shop where they were kind enough to diagnose the problem for me. Error code p2112 came over with a description about the throttle body actuator being stuck closed. They informed me they've seen this problem many times and it seems to be a common issue. It made sense to me because, leading up to this event, I had been experiencing a lagging throttle. It has happened to me twice more since this initial occurrence.
On multiple occasions the car will just lose all throttle response, the car is still running, but will not accelerate. I have to find some place to pull over and shut the car off. Then restart the engine and then it will run good. The issue happens sometimes up six times in one day, and then you can go a week without an issue. I have seen this issue with speeds as low as 20 mph all the way up to 70 mph. From what I have read online it would appear to possibly be due to a defective throttle body. Apparently this throttle body uses a servo to open and close the butterfly that allows air into the intake manifold. I feel this could be a very dangerous problem especially if you are driving and it loses the ability to accelerate and you can not find a safe place to pull over to restart the car.