Engine And Engine Cooling Problems of Ford Fusion - part 1

Ford Fusion 1. 5l ecoboost engines are known to have a fault short block that causes coolant intrusion. This defect does not trigger a check engine light, so there is no way for a driver to identify the problem until it's too late. Ford issued a technical safety bulletin informing mechanics of this issue but customers were not given an option to repair it. A customer satisfaction program (csp) was initiated to replace some VIN models short blocks, but not all. Other Ford 1. 5l ecoboost engines are having this issue and were not properly informed or given the option to repair through the csp and are driving cars that can have total engine failure without proper notification. I have taken my Ford Fusion in for all the safety recalls and was never informed of this issue. I was not part of the csp that aimed to repair the defect because my VIN did not qualify. However, my Ford Fusion 2017 1. 5l ecoboost engine has this same defect and it wasn't caught until damage had been done to the engine and a costly repair was initiated. No check engine light or warning came from Ford to inform me of this issue. I fortunately started hearing noises and went to check it out before taking a long trip in the snow--which could have had disastrous safety consequences if engine failure occurred. I am not the only one with a Ford 1. 5l ecoboost engine that has had this issue. Many people have either not been included in the csp program or were unable to repair in their narrow csp plan window. Ford is waiting for enough complaints to identify if the issue is more widespread, despite knowing that it is a design flaw. This should be a total safety recall as their is no way for consumers to take proactive action against this defect without extensive knowledge of the issues with these engines, which Ford is not communicating to its customers.

See all problems of the 2017 Ford Fusion 🔎.

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!.

See all problems of the 2020 Ford Fusion 🔎.

Vehicle has a known Ford 2. 0l ecoboost coolant intrusion / head gasket defect per multiple complaints on different forums on recently googled searches. At approximately 126,000 miles, vehicle began losing coolant with no visible external leaks, producing white smoke on startup, rough idle/misfires, and check engine light. Vehicle also began overheating intermittently. Heating system stopped working, indicating coolant flow failure. Symptoms are consistent with internal coolant intrusion into cylinders due to head gasket failure, a widely reported defect in Ford ecoboost engines. Issue presents a safety risk due to potential engine failure while driving, loss of power, and overheating. Vehicle requires major engine repair or replacement. This failure occurred despite regular maintenance and appears to be a premature engine defect, not wear and tear. I was recently at the dealership on December 8th with no other issues detected after they replaced a part on my car that failed that I had to pay for ( a p175b-00 ). This had nothing to do with what is going on currently, they ran tests at this dealership and did not detect anything as of December 8th. This was at a Ford dealership. Tests were ran and inspected by manufacturer. Fast forward to a week ago I started having the above symptoms and this was diagnosed by family-friend auto mechanic. I have had multiple issues with this car. The transmission blew at 50 thousand miles, the sun roof leaked ( the seal for the sunroof was defective) into my prnd control shifter causing thousands of dollars in damage, a p175b-00, causing my car to not be able to park, causing chaos for weeks. I have only owned this car since December 2020. I still owe 7 thousand on this vehicle and I am at a complete loss. I really just want Ford to take accountability for this make and model as it never fits the guidelines for recalls on anything. I want justice for myself and others with these multiple issues coming from Ford cars.

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The contact owns a 2018 Ford Fusion. The contact stated that while driving at an undisclosed speed, the vehicle started shuddering violently, hesitated, and failed to accelerate to approximately 35 mph. The check engine warning light was flashing. The contact related the failure to the customer satisfaction program: 21n12. The vehicle was towed to the local dealer, where it was diagnosed with coolant intrusion into the cylinders. The dealer informed the contact that the engine small block needed to be replaced, but a full engine replacement was recommended. The vehicle was not repaired. The manufacturer was contacted and filed a complaint. The manufacturer advised the contact that a future report would be issued. The failure mileage was approximately 100,000.

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The contact's daughter owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed and determined that there was coolant intrusion in cylinder #4. The mechanic informed the contact that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was approximately 92,000.

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Vehicle is experiencing coolant intrusion from a crack in the engine block 3rd cylinder which is a known issue by Ford for my particular vehicle year (2017). Ford has issued a TSB/recall for model years 2017-2019, I believe this issue should qualify for manufacturer recall as this is known issue.

My engine is on my car will not go over 25 miles and if it does it shakes and I place the car in park or shut it off u can hear like water sound coming from the engine were it’s seems as if it was boiling.

Vehicles engine has been affected due to a know manufacturing flaw with design that caused coolant to leak into the cylinder walls of the engine block causing a rough idle, white smoke out of the exhaust and cylinder 2 misfire.

The contact owns a 2013 Ford Fusion. The contact stated that upon starting the vehicle, there was abnormal white smoke coming out of the tailpipe. The contact stated that upon inspecting the oil dipstick, the contact noticed that there was coolant in the oil, and the contact also noticed that there was a small amount of oil in the coolant reservoir. The contact related the failure to NHTSA campaign number: 17v209000 (engine and engine cooling), for which the VIN was included. The dealer was contacted and informed the contact that the recall repair would be performed on the vehicle; however, the contact was concerned that the recall remedy would not correct the failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 109,200.

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The contact owned a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, there was an abnormal sound coming from underneath the hood. No warning light was illuminated. The vehicle was taken to a local independent mechanic, where the engine gasket was replaced, and the vehicle was diagnosed with a warped engine block. The vehicle was repaired. In addition, the contact was informed that there was a coolant intrusion leak and an engine overheating failure. The local dealer was not contacted. The vehicle was not diagnosed or replaced. The manufacturer was made aware of the failure. The failure mileage was approximately 150,000.

Technical safety bulletin 19-2346; coolant infiltrating cylinder #2. Quoted $8350 for long block repair.

Car began leaking coolant, overheating, smoking (white smoke) and misfiring on cylinder #3. Based on my research, this is an issue Ford knows about due to it being a defect in the design, yet I'm being told I have to pay to replace the engine. We replaced the spark plugs, coils, and nothing helped. We took it to a mechanic and were told we need an entire engine replacement and it won't be covered by Ford.

See all problems of the 2015 Ford Fusion 🔎.

During a road trip, received an error message indicating "shift sys fault" after the vehicle would not shift out of park. Upon inspecting the vehicle, it was noticed that the transmission linkage cable bushing was missing. The error message had appeared the day before, but the vehicle would still shift and the error message went away after a few seconds. I was unable to recover the original bushing as it was missing when the vehicle was inspected after the error message. Luckily the error did not happen while driving and instead was noticed while the car was in park. The vehicle has not been inspected by anyone other than myself, and I was able to buy a replacement bushing from a local dealership to replace the missing bushing.

I was experiencing engine vibration while driving and lack of power when I pressed gas pedal. I took it to an independent garage first, and then to the dealer. Both told me there was coolant and water in the cylinders, and the dealer told me I needed a total engine replacement consisting of the long block and the head gasket. And it was going to cost me $14,000. My car only has 44,000 miles on it and Ford told me there was nothing they could do about it even though it was a known issue dating back several years.

See attached document for complaint.

Engine replaced due to flaw in design. I had my 60,000-mile service done and after it was completed, I started having serious issues with my vehicle. Kept getting check engine light cylinder 2 misfire. I took my Fusion back to the dealership, and they advised me that my engine had to be replaced. Apparently when they put my vehicle under pressure during the service it caused the coolant to leak into my engine. I have researched this and found many complaints with the same problem. Unfortunately, the owners of the other Fusions (like me) found out their vehicle was no longer under warranty, and they had to foot the entire bill. Luckly for me, I had purchased the Ford extended warranty, and my out-pocket pocket is $100. I was told by the dealership that Ford is aware of this issue but has not issued a recall. My service advisor was absolutely shocked when Ford authorized the necessary repairs in a couple hours berceuse it normally takes a few days to get authorization. I have owned this car since it was new and have always kept up with the required maintenance. They gave me a rental vehicle and said it would be about 7 days before the repairs are completed.

Coolant intrusion.

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.

Vehicle ran very well, however engine caught fire while exiting highway. Insurance adjuster states common issue with Ford ecoboost engines. Reported to Ford whom dismissed issue of engine fire.

Misfire in cylinder 2 caused by coolant leak into the bore.

According to auto zone, after being placed on scanner, the power train system (p0456) has a evaporative emissions system leak (very small leak) diagnosed at 76,919miles. Ford dealership says they cannot find a problem. When I put gas in the car I have to sit and wait at least 10 minutes before my car will start again. It takes a couple of tries and much hesitation, but it will start. Once you get started it has difficulty accelerating or may slow down on its own. Again, Ford dealership reports they can't seem to find a problem. When I told them the problem, they came up with a price to charge me to fix something they could not find. Ridiculous!! my Ford app clearly states check engine problem detected, but nooooo they cannot find anything wrong. Two different dealerships. Thank god I keep my paperwork because others are complaining of the same thing. They have to put the pen to the paper or we will never get a recall.

I got an engine temperature warning, then I noticed the coolant reservoir was empty. I filled it back up and everything went back to normal. I was driving down the interstate when the check engine light came on. I had a few misfires and was able to make it back to a dealership, who then diagnosed the vehicle and said it coolant intrusion due to an engine block leak. Charging over $9000 in repairs.

Vehicle purchased used at simmons & rockwell on [xxx] mileage 16,323. Mileage 38,559 first engine failure & replaced "new" July 2019, *** indications & doc of 2nd engine failure about 70k mileage) mileage 121,163 second engine failure & replaced "new" August 2022 and finally mileage 189,323 with third engine failure sept 2025 this vehicle had regularly interval oil changes. Always serviced & maintenaced regularly information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Coolant intrusion and requires short block replacement.

Engine diagnosed with coolant intrusion problem into the engine cylinders. Car failed at 138k needing 12k repair from Ford dealership which is more than the value of the car. Transmission shifter bushing went out also in this car even though Ford did a recall for previous years of the model the issue has not been fixed.

The contact owns a 2018 Ford Fusion. The contact stated that upon starting the vehicle, there was an abnormal rattling sound coming from the engine with white smoke coming from the exhaust system, with the check engine warning light illuminated. Additionally, the message “service vehicle soon” was displayed. The vehicle was taken to a local dealer, where it was diagnosed, and the contact was informed that the engine was faulty due to coolant intrusion. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 84,112.

I have a coolant intrusion for my car it is supposed to be recalled and serviced under warranty or the csp.

The transmission failed completely. The vehicle will not engage or shift properly and cannot be driven. The failed transmission is still installed in the vehicle and available for inspection upon request.

See all problems of the 2014 Ford Fusion 🔎.

The contact owns a 2012 Ford Fusion. The contact stated that while starting the vehicle, the power steering assist fault message was displayed. The power steering function was inoperable. The check engine warning light was illuminated due to a possible canister purge valve failure. Upon investigation, the contact linked the failure to NHTSA campaign number: 15v340000 (steering). The local dealer was not contacted, and the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 165,461.

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Coolant is leaking into the cylinders and causing overheating and no start.

This Fusion has the same coolant leak as described in customer satisfaction program 21n12.

Check engine light was on and off intermittently for a few months starting in March of 2025. No immediate problem then, vehicle had 89 90k miles. In August. The vehicles coolant was leaking into the engine . Rendering a misfire in the cylinder and blowing the head gasket after mechanical diagnosis but not checked immediately due to symptoms not occurring till after a few weeks in August. Car not once over heated but then would not start. The car would then not go past a 40 mph without the transmission pushing very hard. After 3rd party mechanic diagnosis, I looked into potential recall on Fords website and in fact there was one but I was never notified of. So I contacted Ford . The said yes, your car is under warranty, however after taking it in, they refused to repair the damages since the problem occurred 10k miles passed the mileage listed on the warranty for the repair. The car is unsafe and not drivable and the issue, which they knew would occur, did not happen till 10k miles passed Fords set parameters in which even if I took it in at that timeframe listed, the problem was not noticeable to be fixed. Very unsafe and unfair to the consumer.

The 1. 5l engine is having known issues with coolant intrusion into the engine under 100,000 miles. Many people are bringing up their issues staying Ford is confirming the mass amount of engine issues with intrusion and quoting $6,000 for new engines. This is absurd because these vehicles should not have an engine known to fail at 100,000 because of leaking coolant into the cylinder. I started losing coolant at 90,000 miles and having to fill it back up.

Shift cable came off the transmission shifter bushing.

Coolant leak into the cylinders. Replaced the first engine for the same issue, this is the second engine.