Brake Disc Caliper Problems of Ford Fusion - part 2

While driving, brake caliper will freeze up and grind on brake pads and rotors, and produce smoke. New brakes and pads were put on 5 months ago, as well as rotors turned. The left rear caliper completely froze. Had caliper replaced several week ago and the same side froze again. This seems to be a rising issue with this make and model and should be investigated.

See all problems of the 2011 Ford Fusion 🔎.

Brakes failed when operating the vehicle. I reverse and the brakes went completely soft. It was difficult to completely stop the vehicle, at lower speeds, but I managed to do so with no damage done to the exterior of the car. I drove my 2014 Ford Fusion awd a few feet to park the car making it easier for towing to the river town Ford's dealership. I saw smoke on the right side of the car coming from the wheel area. I turned off the vehicle to assure no further damage to the brakes and rotors. I press the brakes, while the car was off, and notice brake pressure was back. I confirm it was still unsafe by restarting the car and then a low brake fluid indicator came on and all brake feel went limp to a point that pushing the paddle all the way to the floor board did not engage the brakes, e-brakes I suppose was being used at this point. The next day I get a call from the dealer telling me that the car needed a new brake hose and copper washer on the front right side of the car; the initial cost was 203, then with each phone call, because I wanted part numbers to check cost of parts, the price went to 340 dollars for a brake hose and a copper wash replacement on right caliper, by the way the extended warranty didn't cover this cost so no accommodations for a rental and all cost fell on me the customer because of vague extended warranty information. They also told me that the brake hose was not tampered with it just disconnected/popped out from too much pressure. This happens at 37800 plus miles after the warranty dies out and close to the mandatory 40k dealership inspection service. In the end I paid 289. 66 after pulling teeth with the clerks, who answered the phones, and also calling the manufacture for information about Fordpart. Com website and coverage. Suggest a further testing of this brake failure. Ford should have covered this cost not me for their faulty parts.

See all problems of the 2014 Ford Fusion 🔎.

Power steering assist fault while driving and upon start completely locking up the steering wheel and the brakes keep locking while driving for no reason causing the car to drag, shake uncontrollably. Brakes have been serviced regularly and calipers changes with same results.

See all problems of the 2010 Ford Fusion 🔎.

I was driving home after picking up my 9yr old from school,when vehicle in front of me came to an abrupt stop,I had to swerve right to avoid hitting them and hit my brakes"at this point my vehicle shut off completely in the middle of traffic I had to restart it then drove about 10 miles when my car started chimming and the service power stearing now and advance track control warnings came on I had no control of my vehicle I could not turn the wheel at all it was locked I managed to pull to the side of the road with extreme effort I thought I was going to break something trying to turn the wheel just slitely to get to side of road car had to be towed it undrivable and completely unsafe my son could have been seriously injured. Ford has recalled these cars for the same issue in 2011 and beyond why if they have the same exact function and parts not recalling these 1500$ to fix that I don't have,ive taking great care of this vehicle but have had nothing but problems the same day this happened I received a factory recall for the purge canister and gas tank,the car when I bought it was burning up calipers wheels were coming loose break pads shearing off and rotor after rotor pad after pad and 3 calipers and a battery later because break fluid shot out of my reservoir onto my battery shorting it out conducting a straight feed from pos to neg. Now this this is so dangerous if I was a less exsperianced driver this could have been tragic!!!is that really what it takes for this billion dollar company to be held accountable I mean we already payed for the vehicle least they can do is fix the problems they no have existed for along time before people die.

During adverse weather conditions, such as icy or wet, if I hit a bump or pothole, or take a sharp turn sometimes the abs does not kick in and my brake pedal goes all the way to the floor and the car barely slows down to a stop. If I pump my brakes during this they will work again. This happens intermittently and not every time but when it does I have very little braking power. I have had my vehicle at the Ford moses in st. Albans wv twice and it sits there now. According to complaints and other private mechanics it is my hcu but Ford will not replace because they cannot duplicate the brake failure. It cannot be duplicated because it does not happen every time. According to private mechanics and information they researched it is a valve in the hcu not operating correctly and is a factory defect in the part, however Ford will not admit it is a factory defect. I have had my braking system checked by 2 private mechanics and been to Ford technicians twice with rotors, brake lines, calipers, and brakes inspected, removed and put back on, calipers replaced, brake lines bled, and still having the same issue. I have nothing to upload because the car is sitting at the Ford service department because it is not safe to drive. The problem has occurred while exiting the interstate at 25-35mph, on the interstate at higher speeds, pulling into a parking lot, and pulling into a side street at low speeds, as well as when hitting potholes or bumps in the roads and parking lots but all instances the pavement was wet and my abs should have engaged and failed to.

See all problems of the 2008 Ford Fusion 🔎.

Brake pedal goes straight to floor - no brakes!!! just replaced all discs, rotors, calipers less than 1 year ago. Google forums and you tube videos reflect this is a common problem that seems to occur in these vehicles with abs pump after abs activates. Please please please please please hold Ford responsible for this safety defect!!!!! these are generally good reliable cars and have a lot of life to them. It's a shame that they won't just step up and do the right thing in this situation. Too many complaints to be justifiably ignored.

See all problems of the 2009 Ford Fusion 🔎.

After hard braking and abs activation to avoid an accident while highway driving, brake pedal became very soft. After later stopping and restarting engine (and verifying brake fluid level), petal is still soft / inconsistent. Need to pump brakes to build enough pressure ot stop. Concerned valves on hydraulic control unit is sticking, not allowing full hydraulic pressure to wheel calipers.

After applying the brakes in the rain and the abs activating my brake pedal has been soft since then. I have had the brake system power bled at Ford and serviced with new brake fluid, that didn't solve the problem. I replaced the master cyclinder and that didn't help. I've inspected all the calipers and everything seems to be working fine. After doing research I've seen numerous others have had the same problem. I also seen that you all have a current investigation against this condition. Pe 16-017. I would like to see I can get added to this complaint as I believe that Ford has an issue with its hcu and this is an unsafe driving condition.

On many occasions over approximately the last 20,000 miles (hard to tell how long it has been going on as it has become a normal occurrence) brakes become temporarily non existent after abs is engaged for any reason on both wet and dry surfaces. Petal must be pushed to the floor after such incidents occur in order to stop vehicle and then requires extended distance to come to a complete stop. Since this problem has begun occurring brakes have become soft and all stopping requires petal to be pushed to floor and have to allow extended distance to stop. Have had the same mechanic for over 25 years and he has replaced rotors, pads, calipers, etc as required and says there is no air in brake lines. He has checked all brake components and advised that he recommends replacing the abs hydraulic control unit. After hearing this I began to research the problem online and can't believe the number of complaints out there. I hope Ford is going to stand behind its product and fix this problem. It is a serious safety issue.

December of 2016: while lightly pushing on the brake pedal as I approached a stop sign in snowy weather, I lost my brakes. The rural intersection had a slight incline with no turns, and I first applied the brakes at around 15 m. P. H. There was no sensation (by feel or audible) that my abs had activated and the brake pedal felt soft. Pushing harder on the pedal had no effect, and I ended up gliding right through the stop sign. I didn't think anything of it until it happened again a few days later. I have never had any brake issues on this vehicle besides normal wear and tear. I had a rear caliper replaced in 2014, front brake pads and rotors were replaced in 2015. I recently saw on the news that 2007-09 Ford Fusions were being investigated for brake failure issues.

2008 Ford Fusion. My issue is with the braking system in my wife's car. It will go soft and feel like there are not brakes. While driving car on city, county roads, and some highway. While sitting in idol or park breaks still feel loose and go to the floor. There was an article that NHTSA investigating 2007-2009 Ford Fusions and Mercury milans with the same issue I want to involve my wife's car in this also. Had car at Ford dealer and they found no leaks thought it could be something in a caliper fixed it but it didnt solve the problem.

My 2010 Ford Fusion has a faulty brake system. While driving on a highway, the vehicle's brake pedal suddenly became unresponsive and needed to "hit the floor" to get the vehicle to stop. The brake pedal felt "spongy" and did not seem to be applying the typical pressure as before. The brake system was inspected by a Ford dealership and recommended new brake pads, rotors, and calipers(although the vehicle had been properly maintained and serviced). After replacing all of the mentioned components the issue remained. The dealership then suggested replacing the hydraulic control unit (hcu). The hcu has been identified in forums online as a known problem with Fords to include the edge and escape. The hcu replacement is a costly repair that Ford should be investigating. Road safety should be their priority and brake failure can be fatal.

In situations where a driver is braking and your abs becomes enabled, there is a chance that valves inside the hydraulic control unit (hcu) may stick, greatly reducing pressure sent to the caliper/brake. The valves may continue to be stuck until either the abs is reengaged or until the valves unstick themselves, between periods of hours or weeks. While the valves are stuck, brake peddles will feel extremely spongy and are required to be pressed to the floor to actually have the desired effect of slowing the car. Even when pressed all the way down, the effects of braking are severely diminished when compared to properly working brakes. Reduced braking effectiveness is obviously extremely dangerous for drivers and could, even during clear conditions, cause an accident. Replacement of the hcu costs several hundred dollars and is ultimately a temporary fix, as the issue will eventually reoccur.

The contact owns a 2011 Ford Fusion. While driving 70 mph, the vehicle jerked to the right and made a loud grinding noise. The contact stated that the brake calipers malfunctioned. The vehicle was taken to be repaired. The manufacturer was not made aware of the issue. The failure mileage was 56,000.

Brake pedal goes almost all the way to floor, and is spongy. Car does not stop as well as it should. Have had rotors, calipers, brake pads and fluid changed. Did google search and found this a very common issue with Ford Fusions. The issue is the abs module and pump. A valve inside gets stuck open and when brakes are applied, the fluid just recirculates inside the module, and brakes lose effectiveness.

Brakes are spongy and intermittently do work at all . . Have replaced calipers twice and bled the lines only to have the same problem. Air bag on passengers side is coming apart in dash. Drivers side door handle snapped and the doors lock themselves even with key in ignition running. Looking online I see that many have had the same issues.

The contact owns a 2009 Ford Fusion. The contact stated that the brake pedal traveled to the floorboard several times without warning. The brake calipers and brake pads were replaced more than twice, but the failure continued. The contact was uncertain if the hcu failed. The manufacturer was not notified. The vehicle was not repaired. The VIN was not available. The approximate failure mileage was 145,000.

While trying to stop the car while in motion, the brake pedal goes down all the way to the floor, and it takes longer than it should to stop the car. For several seconds after starting to press the brake, it seems like the car will not stop even though the brake is pressed to the floor. I've almost been in several wrecks and have only avoided them by pressing my brakes well before I have needed to the point of trying to stop at green lights just in case. I have taken it to 3 different Ford dealerships to try and fix the breaks to the point where the brake booster, caliper, and brake module have all been replaced yet the brakes still do not work properly. I hope that this problem can be resolved before someone is killed because he or she was unable to stop his or her car due to the faulty breaks.

During a Ford/Lincoln dealer inspection during an oil cahnge on September 16,2015, my wife was notified that the rear brake pads had approximately 2 mm left and needed immediate service. The vehicle was purchased new in febuary 2011 and at 4. 5 years old has 23,544 miles, this seemed very unusual. According to the service advisor/service manager the front brakes looked fine. Both sets of rear brakes were in very bad shape ( rotors, and pads). Rotors were pitted and scored with uneven wear that were beyond repair. 1 rotor was scored on the back side with two circular gouges several mm deep. According to the service advisor this unusal wear is generally caused by corrosion causing the calipers not to function properly. It appeared to be something wrong causing uneven, damage to the rotors. The entire rear brakes had to be replaced. Not at all expected for this age and mileage car. After voicing my concerns the dealer offered me a 10% discount on the repairs. The worst part was the vehicle was at the dealership in may of 2015. At that time no significant wear was documented. In fact the rear brake lining was documented at 5mm or greater. Since the last service in may the vehicle has only been driven approximately 1200 miles. The vehicle is driven on light highway and city driving. I also own a 2013 f150 with 22,000 miles and have no signs of needing brakes anytime soon. There are several comments on NHTSA , automobile, and Ford's owners websites with similar symptoms. In fact a NHTSA complaint id number: 10610434 described almost an identical set of circumstances.

The brakes on my 2013 Ford Fusion titanium had been improperly "pulsing" for some time. Brought car to my mechanic to check brakes ~7/31/15. He found that rear calipers, pads and rotors were essentially totally worn while front brakes were fine and showed minimal wear. Had to have rear calipers, pads and rotors completely replaced. Mechanic said this sort of brake wear is not normal for a vehicle with ~26,000 miles on it. In fact, in his experience the front brakes usually go before the rear brakes.

See all problems of the 2013 Ford Fusion 🔎.

Replaced all 4 pads and rotors. Drivers side rear is sticking. It has heated up so much it has warped the new rotor. The other 3 stay cool and work as expected. After looking online I found caliper failure very common on the Ford Fusion. I replaced caliper and brake hose. Still sticking. Since I can only get remanufactured calipers, I guess I will have to keep returning until I get one that works properly. These should have been recalled or replacements issued.

First my brakes were just going bad, which was strange because I don't think they were on for over a year yet, I started hearing grinding and a loud thumping noise. Than the mechanic changed brake padres right rotor and caliper, but the brakes wouldn't bleed. Than I took the car to Ford and they couldn't bleed them either, and no one can figure out what the actual problem is. Now when I brake my pedals go to the floor and I here clicking. When I looked up brakes with my car year and model there were people with similar issues.

Brake caliper slide will freeze up and grind on brakes and rotors. New brakes and pads were put on 1 year ago and the left rear caliper has completely frozen up. From doing online research this is a severe problem with this make and model and should be investigated.

I bought my car in 2011 and in 2014 I started having issue with my brakes giving out when I would brake and hit bumps in the road. I would have slam the pedal to the floor to get any reaction out of my brakes or pump my brakes. I took my car in to the dealership to have the brakes looked at. The agreed that the brakes were not reacting as they should. They informed me that my calipers needed replaced. I asked how common that was and they said it was rare to have to replace calipers. I got online and read consumer reviews and realized this was common in my make/model/year of car. I spend over $1,000 to have the calipers replaced and to pay for a rental car while the work was being done. Since then I have adjusted my driving style so as not to trigger my brakes giving out. However, this winter I hit a bump while braking so as not to hit the car in front of me and my brakes gave out again. I was able to get the car stopped by pushing the pedal to the floor, but those extra seconds to get the car stopped and my panic when the car wouldn't brake was terrifying. It's weird because then after a few days it was like my brakes came back to normal, but it was about a week of being very careful with my brakes before they returned to normal. Date & information of incident given is the date & information from the first time this happened in 2014, not the date & information from this year (Jan 21, 2017) when it happened again.

During a Ford dealer inspection (customer satisfaction program throttle body calibration) on July 10,2014, was notified that the rear brake pads had approximately 2 mm left and needed immediate service. I am first owner and at 3. 5 years old and 26,600 miles, this seemed very wrong. Took car to my local mechanic. Front brakes looked fine. Both rear brakes were in very bad shape (calipers, rotors, and pads). Rotors were pitted and scored with uneven wear that were beyond repair. 1 rotor was scored with a circular gouge several mm deep. Calipers not functioning properly and appeared to be sticking causing uneven, major damage to the rotors. Entire rear brakes had to be replaced. Not at all expected for this age and mileage car. Light highway and city driving. No car I have ever owned has had brake problems like this even at 8 years. Numerous comments on automobile and Ford's owners websites with similar symptoms.

Lr brake froze up due to corrosion not allowing caliper to slide properly, causing excessive wear and damage to brake rotor.

The car was inspected by the dealer at 40,000 miles and braking system was rated green ("the pads are okay"). When the car was next serviced at 47,387 miles (within the regular service interval) the left rear brake caliper had frozen, causing the pad to be worn to bare metal. I am worried because brakes are a major safety component, the drag may have damaged the wheel bearing, and I have read (fordfusionforum. Com) of many instances exactly like my own that have led to recurring problems of rear brake failure.

While driving on the expressway the rear brakes seized. When I parked the car the rear brakes were omitting a foul odor and the rear wheel rims were scalding hot to the touch. I took the vehicle in to the dealership who said the springs in the caliper stuck requiring new brake pads, the discs to be machined and a lubrication of all internal components. The dealership stated it is a maintenance issue despite being solely maintained by the dealership and there is no notice in the owners manual or service as to lubricating the internal brake components.

My 2010 Ford Fusion at 33,000 miles required new rear brakes and rotors, because the brakes were grinding and appeared unsafe. This was not covered by warranty because the calipers were not found to be defective. This appears to be a design flaw that will likely reoccur if not addressed by Ford, and could put at risk the safety of myself and my family.

Metal to metal grinding rear brakes at 19967 miles, dealer claims rusty caliper pins, replaced rotors, calipers and pads for $283 out of pocket, not covered under warranty. Front brakes fine and wearing normally.

The rear caliper on the brakes is seizing, similar to what I have heard with many other Fusion owners. A TSB or recall needs to be filed for this as it is unsafe.

2008 Ford Fusion 2wd 4 cyl one rear brake caliper has seized causing damage to rotor, now causing un-even breaking and rotor damage. 15,000 miles are on the vehicle.

The vehicle would randomly lose its breaking efficiency. The brake pedal would go all the way to the floor and would require 3 times more distance to stop. I need to pump the brakes a few times as if im bleeding the system, upon pumping the brakes the system will then feel pressurized and able to apply pressure to the calipers.