Table 1 shows one common other fuel system related problems of the 2020 Ford Fusion.
| Problem Category | Number of Problems |
|---|---|
| Other Fuel System problems |
Purge solenoid unplugged, several times for years, which causes the vehicle not to start up after getting fuel. Check engine light come on often due to this. When I bring vehicle to mecanic shop they plug it right back. P0443 evap purge control valve “a” circuit.
I have a check engine light on due to an issue in the emissions system. The issue is that the purge valve is stuck open. I know that this is an issue that you had a recall on for older models of the Ford focus for this same reason. All the systems of a stuck purge valve are the issues I am having with the vehicle.
My Ford started making a loud noise whenever the accelerator wasn't being pressed, after taking it to the mechanic, he said it is the cracked flex plate. After some light research, it was aparent that this is an issue that Ford's cars have, and Ford has tried to make it better by offering free fixes. I contacted the local Ford dealer and since the car has 90,000 miles, it would have been covered. However, since it doesn't have a clean title, I was declined this service free of charge. I don't agree with this decision since I've been driving this car for over a year since it was purchased off iaa auction, and this issue was made clear only yesterday, but this issue is prevalent in cars like mine. The damage to my car specifically was to the back, and only affected the rear bumper and trunk. Therefore I don't think it is fair that I was declined the serve even though Ford has made it clear it is there manufacturing mistake and they are willing to fix it, just not with cars with my type of title. I was hoping to send in this incident so that this issue becomes a national recall, and more people can get their cars rightfully fixed and aware of this serious issue that can make the car completely unusable before it gets too late. I wasn't aware this was a common issue when purchasing this car, so a recall would protect more people since it will become mandatory information for owners to be aware of this issue. Thank you!.
"the incident occurred immediately after shifting the vehicle into reverse and starting to move. The engine suddenly shut down with a 'system performance' alert, and cooling fans engaged at maximum speed. Moments later, a thermal runaway event began in the high-voltage li-ion battery pack, leading to a catastrophic fire. This is directly related to recall 23v440 / 23s33 (becm failure). The fire was extinguished by the local fire department in telavi, georgia (country). ".
I am reporting a life-threatening incident involving my 2020 Ford Fusion phev. On December 5, 2025, while my wife was driving on a public street, the vehicle suffered a sudden, complete engine failure followed by smoke and fire originating from the high-voltage battery pack in the trunk. There were no prior warning signs or dashboard alerts before the incident. This vehicle was sold via iaai auction in September 2023 without disclosing the active, critical safety recall (NHTSA 23v440 / Ford 23s33) issued in June 2023. This non-disclosure placed my family in extreme danger. When the fire started, my wife was in a state of panic. I arrived at the scene before emergency services. Being a technician, I performed a high-risk manual extraction of the burning battery pack to prevent the entire vehicle and the surrounding residential area from a potential explosion. I risked electrocution and toxic chemical exposure to save lives. The damaged battery pack is currently preserved and available for professional inspection upon request. As a result of the fire and exposure to extinguisher chemicals, I suffered respiratory distress and asthma-like symptoms for several days. I have contacted Ford motor company through official channels and documented all interactions. Ford representatives stated that they 'only assist customers in the united states' and local representatives in [xxx] have officially refused to provide the remedy, stating they are not authorized or equipped for this specific recall. I am now left with a charred, unusable vehicle. I demand a full investigation into the failure of the recall remedy process and manufacturer liability for these life-threatening damages. ( form fields about my location are place holders. Contact me in [xxx] (country) at [xxx] / [xxx] ]. I hope you do don't ignore our lives due to geography. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).
In early October 2025, the vehicle was taken to an independent dealership service department for a routine oil change. Several weeks later, the vehicle appeared to be leaking fluid and began experiencing loud knocking/clacking noises, significant vibration, and drivability concerns, especially during acceleration. On October 10, 2025, while parked at a family member’s residence, the vehicle would not start. Due to safety concerns, the servicing dealership arranged for the vehicle to be towed for inspection. Technicians found a split transmission hose causing transmission fluid loss, which was repaired; however, the abnormal noises, vibration, and drivability issues persisted. Further inspection identified loud popping/clacking noises from the bell housing area. The technician physically inspected the flex plate and documented that the flex plate was cracked. The dealership advised that a cracked flex plate can worsen, cause severe vibration, damage related components, and lead to drivability issues or potential loss of propulsion. Because of the nature of the failure and symptoms, the vehicle was removed from regular use due to safety concerns. The vehicle was later taken to a manufacturer-authorized Ford dealership, which confirmed flex plate failure but stated the vehicle did not qualify for a customer satisfaction program due to engine variant. A goodwill/financial assistance request was submitted and denied. Technician diagnostic documentation from the manufacturer-authorized dealership was requested but not provided prior to filing this complaint. No crash or injury occurred; however, the failure created a risk of sudden inability to propel the vehicle while driving, including at highway speeds. The vehicle remains unrepaired and parked due to cost and safety concerns.
Check engine light keeps coming on saying evap emissions. Have replaced purge valve, gas tank inlet and solenoid. This is the 6th time for check engine light.
Previously reported as a fuel pump issue, incorrect. The mechanic was incorrect. The fuel injectors failed releasing fuel into the engine and the entire system. High risk of fire.
Fuel pump failure. Vehicle is emitting gas from the exhaust system in the back. Not processing fuel as it should. High safety risk.
My 2020 Ford Fusion has experienced three separate flexplate failures, as well as transmission issues following the most recent repair. Failure #1: occurred before I owned the vehicle (confirmed later in the vehicle’s history). The flexplate was replaced by a prior owner in 2022. Failure #2: [8/2023] – while I owned the vehicle, a loud rattling noise came from the engine area. My vehicle was towed to foothill Ford, where it was purchased, and they replaced the flexplate. No power loss occurred. Failure #3: [5/2025] – the same rattling sound returned. I drove it to green Ford, who confirmed the flexplate needed to be replaced, and they replaced it. No power loss occurred, but the noise was severe. After the third flexplate replacement, the transmission began slipping during acceleration. This issue did not exist before the repair, and green Ford had told me the transmission was fine before they replaced the flexplate. Safety concern: repeated flexplate failures and subsequent transmission slipping could cause loss of propulsion or difficulty maintaining speed if the problem occurs at highway speeds or in heavy traffic, creating a potential crash risk. I did lose power on the highway, but was able to pull safely off the shoulder and called a tow truck.
After every fuel up on the vehicle since I bought it in October 2022 car was sluggish to start, it proceeded to get worse as weeks went by and car refused to turn on until multiple attempts. Days later as I was driving and came to a stop light the car was struggling to stay on. The check engine light finally turned on after a few months of struggling with being able to turn vehicle on after fill up. Upon taking it to the Ford dealership to inspect code p0496 and p0456 were found. Upon further inspection I was quoted to need vmv and charcoal canister with reprograming to vmv totaling 1500 worth of repairs. After two days of waiting dealership advised that parts, primary charcoal canister are in back order as "this is a common problem with these cars". Telling me that there is no way of knowing when I will be able to get the parts. Being that my car is a 2020, I don't comprehend why this is even an issue and why is this not a recall.
Ford has issued a recall for which they have offered no remedy. The recall recommends not using the defining feature of the vehicle; the entire purpose for which it was purchased: I. E. The short but meaningful electric range. Ford say the vehicle should not be charged due to an engineering fault that may lead to a fires. The issue has led to thousands of dollars in extra fuel cost and, in my state at least, Ford is refusing to buyback the vehicle.