Brake Disc Caliper Problems of Ford Fusion - part 1

Beginning in 2017, my 2009 Ford Fusion began experiencing decreased braking following engagement of the anti-lock braking system. On 20dec2019, Ford issued recall 19s54/NHTSA recall 19v904. On 04 may 2021, I delivered the vehicle to suntrup Ford westport and reviewed the work to be performed with service advisor jl including repairs for recall 19-s54 and other services. I received a call mr. Jl who advised the repairs for recall could not be completed without additional diagnostic work relating to not being able to bleed the front brakes. When asked if there would be charge for the diagnostic work, I was advised that it would be an $80 charge for 30 minutes of technician time but was also told its likely the brake lines collapsed and there might be caliper issue. I verbally authorized the additional diagnostic work on 05may2021. I received a text message from mr. J. L. Stating to complete recall 19-s54 I would have to pay $820 +tax to replace the brake hoses and that there may still be a caliper issue that may need addressed as well prior to performing the recall work. I called mr. Jl back to decline the work and to prepare the car for pick up so I could get a 2nd opinion. On 06 may 2021, I delivered the vehicle to an independent repair shop requesting a 2nd opinion specifically requesting inspection the brake hoses and calipers and test if the brakes would bleed brake fluid. The technician advised there were no issues with bleeding any of the 4 brakes and no signs of calipers sticking. I contacted a different st. Louis area dealership and was advised to contact them again in approximately 1 month as the parts are unavailable. As of 08 may 2021, I am still experiencing the same issues with the anti-lock brake system as first experienced in 2017 and no repairs have been completed to address the issue.

See all problems of the 2009 Ford Fusion 🔎.

Kayser Ford in madison, WI was supposed to have replaced driver side air bag. I have concerns about their properly replacing, per the safety recall, as tim douglas boasted that "they have over 47 airbags" in back and this is not how the recall should work. The part needs to be ordered per the VIN and received and put in, not some random spare extra parts in back, put in the vehicle, without knowing how long they have been sitting there. Further, this Ford replaced the passenger airbag, and pulled on the bottom edge of the airbag compartment, causing a badly tented edge, that could obstruct the passenger air bag deployment or tear the bag if it is deployed, and affect the angle and trajectory of the deployment. This Ford denied any responsibility. When we had it towed for other repairs including the driver side airbag, they not only did not perform the necessary repairs, but they caused harm to our car: damage to the front bumper, failed to refill fluids correctly, including transmission fluid and power steering fluid and did not replace the front brake calipers. The new serpentine belt is loose and makes a noise. They also drove our car over 30 miles, without our authorization and then lied on the invoice claiming that our car came in and left at the same mileage. Further, they left our car on a tow truck with the j hook hanging from the suspension and under tension, all night.

See all problems of the 2007 Ford Fusion 🔎.

Tl the contact owns a 2008 Ford Fusion. The contact stated while attempting to have the vehicle repaired under NHTSA campaign number: 19v904000 (service brakes, hydraulic), the vehicle was taken to flood Ford of narragansett (21 woodruff Ave, narragansett, ri 02882, (401) 515-2700) where it was diagnosed with needing the calipers to be replaced, in addition to the recall repair. The vehicle was not repaired. The manufacturer was informed of the issue. The manufacturer informed the contact that the calipers were not included in the recall repair. The failure mileage was approximately 165,000.

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While driving slowly into a parking lot to check rear wheel sounds, message "power steering assist fault" appeared on the dash. Extremely difficult to turn wheel and could not backup. Dealer diagnosis on 2/23/21 was "rear calipers seized" and steering gear needs replacement.

See all problems of the 2011 Ford Fusion 🔎.

My vehicle is under recall for a faulty part on the breaking system, I called Ford on Friday 5/22/2020 ( sunshine Ford newburgh NY) and was told they do not have the part and cannot even order it at this time. Also they have no idea when they can order it, it could be months. My car is un-driveable without the new part. I just had the entire breaking system replaced ( calipers, rotors,and pads ). There excuse and response is unacceptable. Please help I need my car to get back to work. Thank you.

My cars back brakes locked up destroying my back calipers pads and rotors. I was able to get the to the shop and the informed me that the abs module was malfunctioning and caused this damage. With some research I found out that Ford issued a recall for this specific problem for every Ford Fusion up to 07/09 my car was manufactured 10/09 and not included in the recall. This issue is the exact same as what they recalled by my VIN was not included.

See all problems of the 2010 Ford Fusion 🔎.

Request to add VIN # to NHTSA campaign id#: 19v904000. Brake pedal always went down more than normal. In June 2018, had rear brake pads, caliper and rotors replaced. October 2018, had front rotors replaced, March 2020 had rear brake, calipers and rotors replaced again. Mechanic bled the brakes and could not establish hydraulic pressure, but tested and there were no leaks. Mechanic said this vehicle should be on the recall list because there is no reason for the brakes to be replaced this often, the fluid is not getting where it needs to be. Vehicle is currently at the Ford service and they want me to pay for them to bleed the brakes when I just had a mechanic do it. My mechanic called them to explain, but since the VIN # is not on the recall, they are not handling this issue professionally. It is the valves within the hbs hydraulic control unit that is prohibiting the valves from closing properly which is why my mechanic could not pressurize the brake fluid in the system. The pedal goes all the way to the ground; the car was towed to the dealership. Therefore, I respectfully request this VIN# be added to this recall so repairs can be made. They will need to bleed the brakes anyway after replacing the valves in the hcu. This car is not driven every day, and sat in the garage most of the time from 2018 to March 2020. I do have receipts with descriptions of work done. This is a school car and I don't want to risk my child being in an accident because of this. Thank you for your consideration and I would appreciate a timely response.

Started out brake pedal would go to floor and it would take greater distance to stop . I had to start using the e brake to stop the car but now I have absolutely no brakes including the ebrake. I have replaced all the brakes including caliper and still break pedal goes to floor and no brakes. When vehicle is off I pump the brakes the pedal gets stiff but as soon bbc as I turn the key straight to the floor. The other day I had to have it towed home because I lost braking completely resulting in me running a red light avoiding a traffic crash and being pulled over. Needless to say I'm very displeased.

See all problems of the 2006 Ford Fusion 🔎.

On two occasions the brake systems failed to work. 1. Driving on rt 4 (double lane state rd. ) in maine speed approx 60 mph. There was 4 to 5 cars ahead of me. Suddenly, everyone applied their brakes. The first car in line decided to take a left hand turn. I applied my brakes-brake pedal went to the floor--no antilock brakes. Had to swerve into oncoming lane. Finally car stopped. A second time it happened was on a hill in dover, nh. There is a traffic light at bottom of hill. As I started down the hill, I applied the brakes again no brakes no antilock brakes. Luckily was able to stop by time I reached the light. I took car to a local garage they test drove and it operated fine. They removed wheels and looked at all the brakes. The rear brakes, calipers, pads etc were replaced a year ago. The front brakes looked brand new even though there was almost 52,000 miles on them. Pads and rotors looked like new, shiny, no sctracthes. Could not find the problem. We decided to replaced the rotors and pads with a softer version. Seems to be working???.

See all problems of the 2012 Ford Fusion 🔎.

Tl the contact owns a 2006 Ford Fusion. The contact stated while driving 30 mph, the brake pedal was depressed to the floorboard but failed to stop the vehicle. The contact stated no warning light was illuminated. The contact continued to depress the brake pedal until the vehicle stopped. The contact received notification of NHTSA campaign number: 19v904000 (service brakes, hydraulic) however, the part to do the recall repair was unavailable. The vehicle was taken to an independent mechanic and the rear brake pads, calipers and drums were replaced. The contact called smith motor CO inc (359 NJ-31, washington, NJ 07882; (908) 835-8100) where it was confirmed that the part was not yet available. The vehicle was not diagnosed nor repaired. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. VIN tool confirms parts not available. The failure mileage was approximately 152,000.

When breaking following an abs event, the brake pedal sinks almost to the floor before stopping the car. This condition persists for an indeterminate amount of time (minutes to days) before self-correcting. I have experienced this on multiple occasions over about two years. I have experienced it after hard braking on snowy/icy roads and after hitting pot holes. This appears to be the same condition as reported in recall 19s54 (abs valve may remain open after abs event) which does not cover my car's model year. My mechanic has done the following work which has not fixed the problem: installed new front and back calipers, pads, and rotors, completely flushed brake fluid, and bled anti-lock brakes using instructions in the Ford ids scan tool.

As a I engage my brake to come to a stop or slow down my brake sinks all the way to the floor. At times my abs will engage if I'm coming to a sudden stop, only on the left driver side. My left driver side tire is showing wear from this event happening quite often. At other times I've had close call accidents due to my brakes not engaging like they should. My yearly inspection is also getting difficult to past by having this brake issue. As far as I know 2006- 2010 models have had a recall due to similar incidents. My 2011 Fusion was manufactured in February 2011 and could have the same parts used. I've looked into the problem before the recall was put in place for the older models and many Ford owners report the brake abs pump being the problem. I've changed my brakes and calipers to see if any would fix the issue but the problem remains the same.

On October 30th 2019 my break was sinking down and was not able to stop in time so I hit stop sign. Since this incident, October 31 2019, the abs module was replaced. The problem continued , I had both calipers replaced, both rear struts replaced. The problem still exists and the brakes have been locking up when the anti-lock brake is engaged. I have taken to two repair shops and they have not found any codes or reasons . Why would this be happening, is it related to the abs hydraulic control units recall?.

When you press the petal, you have to pump the brakes to make the brakes work. The calipers are working correctly and bleeding the brakes doesn't fix it. New brake pads have been replaced. This began once the anti-lock brake system was engaged and the anti-lock brake system won't work. All of the wheels will lock up when there is a sudden stop at moderate speed (40 mph with full braking).

Issue has occurred multiple times since I have owned this vehicle to now. Whenever the abs system engages (hard braking to due snow/ice or obstruction avoidance), immediately following that the brake pedal becomes incredibly spongy or non-existent and braking becomes very difficult without pumping the brake pedal or engaging the hand brake. I've had the pads, rotors, rear calipers, and slide pins replaced and the system flushed and inspected multiple times. I have found that if you pull over ans shut the car off for a few minutes and restart it tends to work until you have the same issue come up. .

The contact owns a 2015 Ford Fusion. The contact stated that the vehicle exhibited multiple failures. The vehicle lost power independently and the brake pedal failed to engage while driving. Also, after fueling the vehicle, the engine failed to start. Furthermore, when the accelerator pedal was depressed, the vehicle would not accelerate. The vehicle was taken to elk grove Ford (9645 auto center drive, elk grove, CA 95757, (916) 478-7000) where it was determined that the windshield wiper fluid penetrated the brake fluid. The brake lines, calipers, and the battery were replaced twice; however, the repairs did not correct the failures and the vehicle continued to stall. The vehicle was taken back to the dealer, but they could not duplicate the failures. The manufacturer was not contacted. The vehicle was not repaired. The failure mileage was not available.

See all problems of the 2015 Ford Fusion 🔎.

My 2011 Ford Fusion hybrid had front end rebuilt. Then about 2 weeks later the right front brake compressed and would not release. This was on orange Ave. Orlando FL. I had to have the car towed to tropical Ford as the brake was frozen in a compressed position. Mileage around 116,000, they replaced the right front caliper, turned the rotor and replaced the pads. Then at 117,000 miles the same thing happened after hitting a bump. The same brake froze in a compressed position. This time on tradeport dr. Orlando, FL. Had to drive to same dealership. Now they tell me that it is probably the hcu/pcm that needs replaced and is apparently a common problem in Fusions and at least one other model. They said a pin goes bad and causes the brakes to engage or compress and will not release. This is a serious safety issue as I was almost hit due to the sudden stop and a recall needs to occur,. This may be out of warranty but is clearly a manufacturing / supplier issue!.

When temperature drops to less than 35 degrees fahrenheit outside rear breaks get stuck and pedal falls to the floor causing car not to stop. Had rear calipers replaced to correct the problem and found out that it is the abs valve body. Also saw other reports and that a recall was being issued only to find that my car was not included. I love this car it has had other recalls and problems but has otherwise been very reliable and Ford has fixed just about all the issues it has had except this.

Tl the contact owns a 2009 Ford Fusion. The contact received notification of NHTSA campaign number: 19v904000 (service brakes, hydraulic) and 21v158000 (air bags) however, the part to do the recall repair was unavailable. The contact called atchinson Ford (9800 belleville rd, belleville, mi 48111, (734) 697-9161) where it was confirmed that the part was not yet available. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The contact stated that shortly after receiving the letter and while driving 30 mph over a railroad track, the brake pedal was depressed to the floorboard but failed to completely stop the vehicle. The contact stated no warning light was illuminated. The contact pumped the brake pedal several times for the vehicle to come to a stop. The contact continued driving to his destination. Atchinson Ford was made aware of the failure. The vehicle was taken to an independent mechanic who replaced the brake pads, rotors, and the calipers. The manufacturer had not been made aware of the failure. VIN tool confirms parts not available. The failure mileage was approximately 96,000.

This issue has occurred multiple times since I have owned this vehicle from 2011 to now. Whenever the abs system engages (hard braking to due snow/ice or obstruction avoidance), immediately following that the brake pedal becomes incredibly spongy or non-existent and braking becomes very difficult without pumping the brake pedal or engaging the hand brake. I've had the pads, rotors, rear calipers, and slide pins replaced and the system flushed and inspected multiple times. No matter what parts I throw at my car, nothing seems to solve this issue.

While traveling on a slightly rough highway, I went around a curve and a bicyclist was in the middle of my lane, I braked suddenly and my brake peddle went to the floor, I had to swerve to keep from hitting him. I pumped my brakes and they came back up, but were mushy and it took several more miles before they worked effectively although still not as they should. The next day the brakes worked fine and for several weeks afterwards, then there was another incident. I was trying to stop at a stop sign, before turning on to a busy major highway and my brakes again went to the floor. The side road I was stopping on was rough (it had been scrapped to prepare for blacktopping). This happened twice within a few weeks. The results could have been deadly. This has happened three times! I had new brake pads, rotors, and calipers put on after the first incident and it did not help.

While turning out of the driveway into the street the brake petal pulsed as if the antilock brake system was activated. Immediately after that the brake pedal went to the floor with no brakes being present. Pumping the brakes restored a little of the pedal pressure. After that the brakes remained spongy. We replaced the brake master cyljnder but were unable to get any pressure in the brake system even after bleeding the brake lines. The dealer said that it was the abs control module. There should not be a part that can fail while driving that can physically take away all of the break pressure in the system. In researching on the internet I have found hundreds of cases of people saying the same thing happened to them with their Fusion. The problem seems to be that one of the valves in the abs control module can stick in the open position creating a loop in the brake line system that allows the fluid to circulate instead of pressurizing the wheel calipers.

Problem with brakes, spongie, going to the floor even after I replaced brakes rotors and calipers the whole way around the vehicle. Does not happen all the time only 50,000 miles on the vehicle. Mechanic told us nothing was wrong. But why does it continue to happen. This is unsafe and I have almost been involved in 2 accidents due to brakes failing. How do I get this fixed and how can I have this taken care of. It is worse when it is wet or raining out. All of a sudden brakes go to floor and you are unable to stop even when pumping the brakes.

Coming home from late night movie with my 10 year old son. Pulked up to 4 way intersection across from my driveway at 10am angle when I got my breaks to stop at 4way pedal went to floor I had no breaks. Ive already replaced multiple calipers break pads every 2 months and rotors cause I've had nothing but serious issues with the breaking sytem. But I had to angle my car at the wall in my driveway and hit to stop.

Low brake engagement following anti-lock brake system event. Vehicle was in motion. After this event, I would need to push the brake pedal down more than it should need to be pushed in order to get the brakes to engage. Tom holzer Ford in farmington hills, mi replaced a hydraulic control valve unit as well as a front right lower side caliper pin that was frozen.

Random failure of left front brake hose from body line to brake caliper. Vehicle had only 66,214 miles on odometer. Hose failed with zero warning during normal brake usage while driving in straight line resulting in almost no braking power. Zero signs of physical damage to hose. Contacted dealer. Dealer indicated that original factory p\n was obsoleted and a new p\n was being issued. Decided to replace all (4) brake hoses for fear of another failure. I have retained the factory parts that were replaced.

See all problems of the 2013 Ford Fusion 🔎.

Tl the contact owns a 2012 Ford Fusion. While attempting to stop the vehicle, the brake pedal traveled to the floorboard and the braking distance was extended. The vehicle was taken to an independent mechanic who replaced the brake pads, rotors, and calipers, but the failure continued. The mechanic diagnosed that the anti-lock braking system was faulty and needed to be replaced. The vehicle was not repaired. The local dealer and manufacturer were not notified. The failure mileage was 94,000.

Tl the contact owns a 2009 Ford Fusion. While driving approximately 45 mph, the brake pedal became soft and failed to stop the vehicle. There was no warning indicator illuminated. The vehicle was taken to friendly Ford (734-243-6000, located at 2800 n telegraph rd, monroe, mi 48162) where it was diagnosed that the calipers needed to be replaced. The calipers were replaced, but the failure recurred. The vehicle was taken back to the same dealer, but the technician was unable to duplicate the failure. The manufacturer was not made aware of the failure. The failure was not remedied. The failure mileage was approximately 88,000.

Brake pedal travels all the way to the floor after abs event. Braking is now compromised. No trouble lights or abs codes. Bled brake system, replaced all calipers and pads, problem not resolved. Replaced abs pump and control module, problem resolved.

Vehicle was in motion after exiting the freeway from a 45 minute drive at 70 mph. Brakes needed more pressure than normal to slow and stop the car. Once vehicle came to a stop and without applying any additional pressure to the brake pedal the pedal became spongey and moved completely to the floor. I shifted the vehicle to park and tried the brakes again, this time it felt ok. I continued driving and the pedal continued to do this over and over again. I pulled into a auto parts store and checked the brake fluid, the reservoir was not showing any fluid. I proceeded into the store purchased additional brake fluid and topped off the brake fluid. Upon getting back in the vehicle I tried the brakes several times and could not get a firm pedal. I got back out of the car and inspected each of the wheel areas. Upon reaching the right front I found brake fluid running out from underneath the vehicle. After closer inspection the flex line to the caliper had failed and was spraying brake fluid when the brake pedal was pressed and sucking air into the system when the brake pedal was released. This entire time the car never reported having anything wrong with the brakes. There should have been a warning light that the brake fluid was low. Additionally, this car only has 47,000 miles on it, this line should not have failed this soon.

Passenger side caliper locked up replaced it 3 days later it locked up again then the driver side locked up replaced it lasted a week then it locked up again got a defect replacement 3 days later both front wheels locked up I allmost got hit from behind had to force drive the car off the road with both wheels smoking so bad it melted the center caps off the wheel the stick on weights fell off.

I have very little braking power. There is no possible way to lock my brakes up in case of an emergency. The brake pedal sinks all the way to the floor. Yes it slows the car and yes it stops the car but if someone makes a sudden stop in front of me my car will be in a accident. I was gonna replace calipers but a mechanic said they weren't bad they were wearing normal. The brake pads are less then a year old and the rotors were replaced the same time. I have almost been in a few accidents because of this issue luckily in iowa we have big shoulders that gave me plenty of room to swerve to the shoulder and avoid an accident. These incidents all happened on highways as I was driving to work and the speed limit is 65 which with brakes that barely work I'm scared to even get to that speed. Normally I drive my other vehicle because of this problem that I have with the brakes. So I spend alot more money on fuel then I should considering I bought this car for the good gas mileage.

Brakes have on two occasions got weaker. When pressing on the pedal, it went almost to the floor and was "mushy" feeling. I'm an engineer and did some research and it appears to be in the abs hydraulic system. I did some testing and could not get it to repeat, including some off road driving putting the car into skids, etc. Neither could my mechanic find the issue. He had heard of this issue and said it is near impossible to diagnose. We are original owners with 130,000 miles. The mechanic replaced all four calipers (new shoes, etc) and ensured they were no sticking. These two incidents occurred for the first time this past year.

The contact owns a 2009 Ford Fusion. While the brake pedal was depressed, the vehicle failed to come to a complete stop. The contact applied excessive force to the brake pedal. The contact was concerned of a future injury. There were no warning indicators illuminated. The vehicle was taken to an independent mechanic where the rear passenger side caliper and brakes needed to be replaced. The vehicle was repaired; however, the failure recurred. The vehicle was then taken back to the independent mechanic where the abs modulator needed to be replaced. The vehicle was not repaired. The dealer was not contacted. The manufacturer was notified of the failure and provided case number: cas13938410. The approximate failure mileage was 125,000.

Right rear caliper is locked again, evev after it was replaced. It wears the right rear brake pads while drivig. The brake pads are constantly smoking while driving and the rotor is too hot to touch and the pedal goes to floor when the car is stopped at anytime. The vehicle is now parked, because it is too dangerous to drive. The cost of repair parts when I last checked was over $1,200.