Body problems of the 2012 Ford Fusion - part 1

79 problems related to body have been reported for the 2012 Ford Fusion. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2012 Ford Fusion based on all problems reported for the 2012 Fusion.

1 Body problem

Failure Date: 04/24/2025

Absolute unacceptable level of rust to the body and frame. Even with regular car washes, sitting for a year covered. It’s literally totalled and I am out of a car. It’s a 2012 with this amount of rust.

2 Body problem

Failure Date: 11/23/2024

Driver door is not locking. Tried with manual key too but not successful. Tried to open door from inside but no success. Looks like door assembly or spring is faulty and designed poorly this can be a safety hazard as driver can't get out of car easily. Pls recall all Ford Fusion 2012 and ask dealers to fix it. I checked few articles forums and youtube videos and everywhere it says there might be a spring problem or some plastic issue in latch or door assembly.

3 Body problem

Failure Date: 03/22/2023

This is the second time my door latch has malfunction. I'm a single parent and to keep having to come out of pocket to get the same issue fixed is a big inconvenience. The inside is broken I have to roll my window down and unlock my door from the outside just to get out of my car. This is a major safety hazard why hasn't the recalled 2012 Ford Fusions been included for the door latches? I can't even lock my door and there has been numerous break-ins close by.

4 Body problem

Failure Date: 03/05/2023

Driver inside door handle does not allow the door to be opened.

5 Body problem

Failure Date: 11/01/2022

Front driver side door handle mechanism breaks and will not open the door when the lock mechanism is in the unlocked position. To open the door from the interior, the driver must roll down the electrically-powered window and use the exterior latch to open the door. There are multiple examples of these situations and the owner’s description of repairs. Here is one example: https://youtu. Be/at96diapyc8 this is a serious and significant safety hazard for the vehicle driver, particularly in the event of a vehicle fire or water submersion.

6 Body problem

Failure Date: 10/01/2021

Door handle open mechanism failed (of driver side door) thus causing a safety issue because you cannot exit the vehicle when inside, except by rolling down the window. This issue has been reported by several other owners.

7 Body problem

Failure Date: 06/24/2021

Over the past few days driver side door would not open from the inside of the vehicle. Rolling down the window and opening the door from the outside is the only option in opening the driver side car door. This is a safety concern as if I were ever in need to exit the vehicle in an emergency manner I can not easily or quickly get out of the car we’re under water, on fire, etc. My vehicle is not the only vehicle that is having this issue, I have heard reports from mechanics, other Ford Fusion drivers, and personal experience that Ford Fusions from about 2006-2013 are having this issue. The issue needs to be addressed for safety concerns and is only happening on the drivers side door.

8 Body problem

Failure Date: 06/08/2021

Door latch keeps falling have to roll down the window to open the door from the outside.

9 Body problem

Failure Date: 04/11/2021

The driver door opened while I was driving and I am certain that I closed it before driving. Then, the inner handle prevented my door from being opened from the inside causing me to have to roll down the window to open the door. A week later, today, and the lock handle has now fallen off. Notice photos of broken lock that fell off, also, the door handle has zero tension with only a finger causing the door handle to be inoperable.

10 Body problem

Failure Date: 10/24/2020

When I was preparing to exit my vehicle at a construction roadway (I was lost) my drivers' door handle would not open- it flopped. I could not exit. I called my family for help to find out what to do. (I am a senior and could not climb over the stick to use the other door) my family said to lower the window and open the door from the outside and "be carefull!" after that I went home and when I tried to close the door- it would not latch/nor close- once again I called for help and was told to tie the door close thru the windows. Which meant my door was vunable to theft and weather. When I spoke with the Ford dealer service department, I was told that this is "a common problem with older models"(mine is a 2012!). Per the dealer it requires a door lock part. What it tells me is the safety features on "older models" expire with the warranties! but this is why I purchased a Ford!! had I know the "safety features" expire with the warranty, I would have researched which vehicle has the best & longest "safety features"! I now feel unsafe driving this vehicle due to my inabilities to exit in case of an emergency due to faulty/expired "safety features!" it makes me feel I would be trapped without a way out! if this is common-why isn't it stated somewhere for seniors to know in advance- especially before purchasing a Ford with common safety defects!? how many seniors/owners have to become injured or die before Ford reports this as a failed safety feature??!! airbags, seatbelts, . . . - door locks on driver's door should be added to the recall list before it results in many injuries/dealths! it is a cheap part to replace per Ford dealer and could be reason why it is not a recall but at least it should a notice sent to owners so they can avoid it happening to them. Luckly my incident occurred in daytime- this could have been worse at night!?.

11 Body problem

Failure Date: 04/13/2020

My passenger front side door lock will not (unlock or lock) while the car is in motion or stationary. It is stuck in the locked position when I use my key pad and trying to use the unlock button in my car. I'm also having difficulties with the my driver side door latch while stationary. When I'm ready to exit my car after driving, I urn off my ignition; open my driver side door; and shut the door but sometimes the door latch get jammed and not want to close (the latch would be facing down).

12 Body problem

Failure Date: 02/02/2020

Driver's door latch stopped working. Suddenly could not open the door to exit vehicle after parking it. Door does open from the outside but not from within.

13 Body problem

Failure Date: 01/27/2020

Door on drivers side lock jams. Driver has to open door from outside. Are there any recalls for this car door locks?.

14 Body problem

Failure Date: 12/18/2019

Driver side inside door opening handle broke twice. I fixed it with a used part from the exact same year and model of car with similar mileage, but it broke again in 3 months time. It's not just a pain in the butt to get out, it's also a safety issue. If a person was in a wreck and can't open the electric window how would I exit the vehicle in a hurry? this happened as I was attempting to exit the car after arriving at work. There is a small thin plastic piece that breaks off of the handle you pull to open the door, once it beaks the only way to get the door open is to lower the drivers window, reach outside to get ahold of the outer door handle to open it from there. If you can't do that you must crawl over the passenger seat to exit unless someone can open the door for you.

15 Body problem

Failure Date: 07/23/2019

Driver side door latch will not latch and stay shut. There was a recall for door latches in 2013-2014 (recall 15516) but my 2012 VIN is not included in any recall. This just occured yesterday and now latch will not keep door shut. Car stationary. Unable to safely drive my car because door will not stay closed.

16 Body problem

Failure Date: 07/01/2019

Squeaks and creaks heard while driving over bumps and turning can be caused be a couple common sources and should be carefully diagnosed. Possible weld issues on the lower control arms can cause the noise concern.

17 Body problem

Failure Date: 03/29/2019

Driver side door will not open from the inside. When inside the vehicle the door handle feels loose and moves freely when pulling but the door will not open. You can open the door from the outside.

18 Body problem

Failure Date: 01/16/2019

I was parked. I was sitting in the driver's seat trying to get out of the driver's side door. I pulled on handle and something inside the door broke. I could pull the handle but the door would not open. I could not open the window because the window was frozen shut. It was quite terrifying thinking I would be stuck in the cold. Then I realized I could exit through another door but I had to crawl into the passenger seat from the driver's seat. If this had been an emergency situation, I don't think it would be safe for the door to lock shut like that. Since then, I have not been able to open the driver's side door from the inside, and if I can't open the window in freezing weather to reach outside (from inside) the car to open it, I have to crawl to passenger's seat to get out.

19 Body problem

Failure Date: 01/02/2019

The drivers side door will not open from inside at all. I have to have someone open it from the outside for me or roll down the window twist around in the seat and open it for myself. I then have to roll the WI dow back up. I have only 72120 miles on this car. It is ridiculous. I can easily get trapped inside in an accident and not be able to get myself out. I called the dealership and was told that it was not under warranty and I would need to fix it at cost. I am the only owner of this car how is that possible? I looked online to see how many others have had this issue and it is a serious problem. How has nobody gotten killed by being trapped in the car? luck! I am scared to drive it since it is winter and know my fellow drivers are not as cautious as I am. I need to save up money to be able to get this fixed yet I am scared to drive to work. What a crazy world we live in. U will never buy Ford again and it was brand new.

20 Body problem

Failure Date: 11/17/2018

Drivers side door handle doesn't work. Door can not be locked. There is a safety recall on the 2013/2014 Fusion for a similar issue.

21 Body problem

Failure Date: 10/26/2018

This is the 3rd complaint for the same problem. The door locking mechanism inside the door broke on the drivers side twice and once on the passanger side. The door would not lock while traveling down the highway. In an accident the door could fly open. The right rear door lock also broke once. I have had Ford repair the left front door once and the r front . Ford would only pay for the right front door. This car was not in an accident on any of the doors. Ford would not pay for the left front and the right rear doors. Now the left front door is broken again. Which Ford said it was not under warranty. The car has only 68000 miles. Ford case #16185723-s-5h6r8.

22 Body problem

Failure Date: 08/17/2018

Today after parking and turning off my car, I could hear the automatic locks disengage but my driver's side door could not be opened from the inside. I tried to manually unlock it and it doesn't move, I tried using the key fob to lock or unlock the door and I tried the automatic lock button on the door. I had to restart my car, roll down the window to open it from the outside to finally get out.

23 Body problem

Failure Date: 06/07/2018

A couple days ago, I got to work and the front, driver-side door would not open from the inside. It unlocks just fine, but the only way to open it is to roll down the window and open it from the outside.

24 Body problem

Failure Date: 05/13/2018

It was a chain-collision. The Lexus in front of me slammed into an Acura, and I slammed into the Lexus at about 50mph. Severe damage to my car (it has been deemed a total loss by ins. ) we were southbound on I-35 near the continental exit in dallas texas on Sunday may 13 2018 at about 3pm.

25 Body problem

Failure Date: 05/01/2018

Tl- the contact owns a 2012 Ford Fusion. The contact stated that approximately two years ago, the passenger's side front door handle failed to unlock the vehicle from the outside. The contact stated that over time, the driver's side and passenger's side rear outer door handles also experienced similar failures. The vehicle was first taken to chino hills Ford (4480 chino hills pkwy, chino, CA 91710). The contact was informed that there was a diagnostic fee to have the vehicle diagnosed. The contact declined to pay to have the vehicle diagnosed. The failure worsened and Ford of upland (555 w foothill blvd, upland, CA 91786) was contacted and informed of the failure. The contact was provided the same information as the previous dealer had provided. The vehicle was not repaired. The manufacturer was contacted and informed of the failure. The failure mileage was approximately 90,000.

26 Body problem

Failure Date: 03/12/2018

Driver side door will not open from the inside or the outside. I fear that if in a collision, I could not escape. I see there was a recall on the 2013- 2015. I feel that Ford should correct this deficiency on my vehicle. This is when vehicle is station and moving. This happened in March and I thought the locks may have been frozen, and now it is happening again.

27 Body problem

Failure Date: 03/03/2018

Tl- the contact owns a 2012 Ford Fusion. The contact stated that all the door handles did not work from the inside of the vehicle. There was no warning. The contact stated that the windows needed to be wound down in order to open the doors from the outside. The contact called the future Ford of clovis dealer (559-862-1570, located at 920 w shaw Ave, clovis CA 93612) where it was stated that there was no recall. The manufacturer was made aware of the failure and referred the contact to the NHTSA. The failure mileage was unknown. Fe.

28 Body problem

Failure Date: 02/25/2018

When trying to get out of my car, the door wouldn't open. The door was still latched, but I tried to continue driving to the nearest auto shop. While driving on the door latch came undone and the door came open while driving. At this time the door will not open from the inside (I can open using the exterior handle) and the driver door does not lock. The latching issue is the biggest concern as it could cause injury (I'm very thankful it didn't fly open while driving on the highway two minutes earlier).

29 Body problem

Failure Date: 02/02/2018

I own a Ford Fusion and several months ago the rear passenger side door handle stopped working. It appears that the hinges broke and the doors could not be opened from the inside and then 2 months ago the driver side door did the same thing. I went to the dealer and was told that it is common problem with the Fusions and several customers has been coming in with the exact issue, and Ford won't offer a recall. Just to have one door handled fixed us costing me $345. This is 1/3 of my salary every two weeks. 2 years ago the engine stalled on the highway while driving now I have to put up with not being able to get out of the car from the inside. I have to roll the window down and open the car from the outside in order to get out of my car. In the event of an emergency I would not be able to exit the vechucle. Ford needs to offer a recall on these parts.

30 Body problem

Failure Date: 01/05/2018

The contact owns a 2012 Ford Fusion. After switching to the park position and turning the vehicle off, the front driver side door would not unlock from inside the vehicle. The contact was unable to immediately exit the vehicle. The door was able to be opened from outside the vehicle. The vehicle was taken to buff Ford (111 s. Il route 31, mc henry, IL) where it was diagnosed that the door handle was faulty and needed to be replaced. The vehicle was not repaired. The manufacturer was notified, but no solution was offered. The failure mileage was 51,000.

31 Body problem

Failure Date: 12/17/2017

The front, passenger-side door does not lock all the time. To get it to lock, you have to hold the door latch closed and manually press the lock lever on the door. Locking it with the fob doesn't work, nor does pressing the lock switch (that normally locks all the doors in the car).

32 Body problem

Failure Date: 11/21/2017

Not near home and daughter getting in vehicle in the passenger rear when door would not latch shut. Latch was/ is in the open position. Car was stationary. This is door number 3 of this vehicle to have issues with doors staying closed or getting them opened from similar situations. What if this were to open as I was driving and this part were to give as I was driving down the road?.

33 Body problem

Failure Date: 11/16/2017

I was on the road pack saddle in jonestown TX 78645, when I pulled on to road 1431. A large truck with a crash guard hit me on the driver's side @ 60mph. The accident turned my car into a horse shoe, and senjt me into on coming trafic. All of the air bags were activated and saved both me and my wife but, the residue that came with the activation pepperd me in the face and ruined my glasses. If I had not had my glasses on,I would have lost my vision due to such. We were on a county road. Turning left and my vehicle was in motion.

34 Body problem

Failure Date: 11/01/2017

The front driver door will not open from inside thee car. I was parked and ready to get out at work.

35 Body problem

Failure Date: 09/14/2017

The inner driver side door handle broke suddenly when trying to exit the vehicle. The handle made a pop sound and we were unable to get out. Once we had the chance to look at what happened, we noticed that pulling open the handle at the same time as the lock engaged the latch. The vehicle was parked at the time of the handle breaking, and the motor was turned off.


Other Structure related problems of the 2012 Ford Fusion


Safety Ratings of Fusion Cars
Fuel Economy of Fusion Vehicles
Fusion Service Bulletins
Fusion Safety Recalls
Fusion Defect Investigations