Four problems related to wiring 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.
Tl the contact owns a 2012 Ford Fusion. The contact stated that the vehicle was difficult to start. The vehicle was towed to franklin Ford (175 e central st, franklin, MA 02038 508-570-4022) to be diagnosed. The contact was informed that the wiring under the dashboard had a corroded solder point. The contact stated that there was a short circuit in the wiring harness. The contact stated that several repairs were performed at a cost of $3,000 however, failed to fix the vehicle. The manufacturer was made aware of the failure. The approximate failure mileage was 133,000.
When I turned on the fan to circulate heat or cool air nothing happened. The blower motor for the ac and heating has failed 3 times in the last 4 years; 12/13/2013, 6/24/2015, and 5/26/2016. The last time the Ford dealer had to replace the entire wiring harness as well. The last repair cost $730. Angela keevis, Ford motor company customer service manager, told me there was nothing they could do for me since I had already paid for the repair. My son needed the car for his high school senior prom so I needed to pay the bill ASAP.
Purchased a 2012 Fusion sel with 35xxx miles in feb16. During the summer of 2016, the a/c blower began to function intermittently � manipulation of the wire harness supplying power to the resistor would cause the blower to turn on/off. The blower only ran at one speed (I. E. The resistor was bad). The blower and resistor were replaced. The issue is once again occurring at ~80,000 miles. This is a well-documented complaint (blower pull too much current and fries the resistor) with this vehicle and, oftentimes, Ford dealers are only replacing/repairing the blower and resistor. However, in my experience (and likely many others), the wire harness also needed to be replaced to correct the issue as continuity through the wiring is also affected when this issue first occurs. This is an obvious manufacturing defect that Ford is not addressing. Furthermore, their dealerships/service center personnel are not adequately educated on how to permanently correct this issue (this is evident by the number of complaints that reference the issue recurring after only the blower motor and resistor are replaced). They are charging Fusion owners $500+ to put a temporary band aid on an electrical issue that should be well understood by now.
The connector to the air control relay overheats. Would smell an electrical burning scent. Checked online found pictures of melted wiring under dash. Took pictures of that area under dash and found the same thing. The connector to the air control relay is melted. The blower fan has quit working. Ford dealerships want 500. 00 plus to fix this. I would call this a safety defect. It only seems to happen to cars equipped with the duel control auto climate. This incident did not cause a fuse to trip and could lead to a fire in the dash. It not uncommon because it was quickly and easily found on youtube. Ford was aware of the problem, but denied is was anything other than a maintenance issue.