Four problems related to manifold/header/muffler/tail pipe have been reported for the 2015 Ford Fusion. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2015 Ford Fusion based on all problems reported for the 2015 Fusion.
2015 Ford Fusion 1. 5l ecoboost engine. Engine coolant leak - blown inner cooler assembly and coolant intake manifold assembly. Problem initially noticed while driving on freeway. Engine temperature guage momentarily spiked while driving. No smoke or unusual noise noticed while driving. Pulled over and noticed coolant overflow tank near empty. Coolant refilled an driven home. This happened on 9/28/2019. Took to ntb next day on 9/29/2019 to have pressure test on coolant system. Car sat till Monday 10/30. Ntb misdiagnosed issues stating overflow reservoir had slow leak. On 10/1 ntb identified that there was a blown gasket somewhere on the cars engine that caused coolant to leak into engine. 3 of 4 spark plugs saturated with engine coolant and car would not start. On 10/1 car immediately towed to nearest Ford motor service center. Engine technician stated that engine inner cooler assembly and intake manifold assembly had blown and coolant entered the engine. This resulted in nearly $1,400 worth of initial repairs and poses a safety hazard. Ford engine technician stated he has seen a similar issues on quite a few of these cars. Upon investigation I have found that in 2017 the 2013-2014 Ford Fusion had a recall for related issues that caused coolant to leak into the engine and may possibly cause the engine to start on fire. Currently many customer reports on the 2015 Fusion as well but no action on Ford motors behalf.
We have a 2015 Ford Fusion se. We were the 2nd owner and purchased from a dealership. While driving the car it started sounding like fluid in the dashboard and the car started shaking. Then it started blowing out tons of white smoke out the tail pipe, then the check engine light came on. We pulled over, parked car. Let sit and cool down. There was oil, transmission fluid, and coolant in the car. We have done all oil changes and maintenance regularly. We had the car towed to the dealership. After several days they came back stating it is a manufacturer defect and that basically the car sucked in coolant through the engine and was burning (reason for white smoke). It ruined the engine. The manufacturer warranty was over at 60k miles. . . . . . . . We have 65k and Ford is refusing to cover the issue even though this is a defect that on their end. Also the intake manifold was replaced at 46k miles. How can Ford state that they are not responsible? we paid $16k for a car we have had barely over a year and now a pile of scrap metal.
The contact owns a 2015 Ford Fusion. The contact stated that while driving at 40 mph, the vehicle lost power without warning. The vehicle was towed to an independent mechanic where the mechanic was unable to provide a diagnosis. The vehicle was then towed to sayville Ford located at 5686 sunrise hwy, sayville, NY 11782 where it was diagnosed that coolant was leaking and being burned inside the engine manifold and the cooler intake manifold, related gaskets and seals needed to be replaced. The vehicle was repaired, however, the check engine light illuminated and the vehicle was taken back to sable Ford, where the vehicle had not yet been diagnosed or repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with NHTSA. The approximate failure mileage was 83,000.
While driving, my vehicle overheated. Checked coolant level, and it was less than half full. I refilled coolant to recommended level, and proceeded to drive. Two weeks later, it overheated again, and my coolant was low again. Refilled and monitored for leaks. No leaks. Then vehicle began misfiring. Diagnosed with cylinder 3 misfire. Replaced spark plugs and coil packs. Still misfiring. Rediagnosed with cylinder 3 misfire. Then it just died. Would not start. Acted as though it was flooding. Diagnosed with no additional issues by dealership. Then discovered TSB for a bolt that was backing out of the intercooler and into the manifold. This issue was allowing coolant to flood the manifold and cause misfiring. Got that fixed as well as the catalytic converter and turbo unit for the car which were damaged as a result of the coolant issue. $5,000 in repairs for a manufacturing defect that could have left my family and I stranded in the desert heat without a/c or in the sub-zero snowy mountains without heat since the vehicle would not even start. As a family, we travel extensively. This is definitely a safety issue!!!!!.