Manifold/header/muffler/tail Pipe Problems of Ford Fusion

Drove my 2014 Fusion with approx 141,800 miles on it to work (approx 30 miles) the night of 8/25/2020 with no issues or warning lights upon parking in the parking garage and exiting the vehicle. When I came out the next morning it failed to start with the remote. When I got in and tried to start it, it still would not start and it provided no warning lights. Had someone attempt to jump it which obviously didn't work, so was it towed to a nearby Ford service center. The summary of their diagnostics was as follows: there was no coolant (which I had put some in about 3 weeks prior, after the car did provide a warning that it was overheating. I had presumed that the Ford quick lane forgot to check my coolant levels when it was there 5/13/20 and at this time it was low but not empty), spark plug number 2 had coolant on it, cylinder #2 also had coolant in it, and after cleaning all spark plugs and reinstalling them white smoke was coming from the tail pipe which smelled like coolant. It was requested that I replace the battery and get a new engine at which they gave me a quote of $6526. 86. After doing research and asking a non-Ford mechanic, he agreed it was a Ford defect. Ford was notified via phone and a case number was provided, but said they could not help with this matter. This is the same issue the 1. 6l and 2. 0l had that was recalled and Ford acknowledges the issue with the 1. 5l in ssm 48106. Really sucks because the car runs great other than this issue and is currently parked while making a decision to fix or sell. Note: all routine maintenance work on this vehicle has been done by Ford.

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I was driving down the road it begin to spudder and had hard time going. White smoke was coming from tail pipe and when I pulled over and popped the hood there was so much smoke coming from the engine where you put oil in. I was afraid it was fixing to catch on fire. Even had someone pull up because he thought it was on fire. My car will not start now.

I have a 2017 Fusion remote start and I've been told I need to replace my engine due to coolant leaking into the cylinders/engine. Car stalls on the highway and won't go over 20 miles then it kicks back up. Smoke coming out of tail pipe.

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Started out as cylinder 3 misfire, normal highway driving, I replaced plugs and coil packs, did not help. Then engine over heated, checked coolant which was low. Shortly after realized coolant has been leaking to nowhere and white smoke started coming out of the tail pipe. After some reseach I find out this a problem Ford knows about, so im hoping they are held responsible.

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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.

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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.

Car caught on fire on the way to work one morning due to oil leak near exhaust manifold. Looked to find where oil leak was coming from, oil leak is coming from a crack in the cylinder head right above exhaust manifold.

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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.

The contact owns a 2013 Ford Fusion. The contact received notification of NHTSA campaign number: 17s09000 (engine) however, the part for the recall repair was unavailable. The contact stated the manufacturer exceeded a reasonable amount of time for the recall repair. The contact stated that the vehicle was over heated which caused excessive smoke to emit from the vehicle's tail pipe. The contact took the vehicle to the dealer where the vehicle was diagnosed but the results were unknown. The vehicle was not repaired. And the failure recurred. The approximate failure mileage was 138,000. The manufacturer was not made aware of the failure. VIN tool confirms parts not available.

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!!!!!.

2016 Ford Fusion. Consumer writes in regards to head gasket and exhaust manifold issues. The consumer stated the engine was replaced twice, the power steering and various sensors were replaced twice as well. The manufacturer was notified, but could not determine the failure.

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Driving on a busy interstate highway when suddenly my car looses power and goes into limp mode. Absolutely no throttle response. Wrench light indicator came on. I pulled over to the side of the road and my car shuttered a bit as I slowed down. Turned the car off and waited a minute before restarting. Restarted sluggishly. Began driving again and no more than 5 minutes later, the same thing happened. This time the check engine light came on. Once again, turned car off, restarted and began driving again. Made it into a local brake/muffler shop where they were kind enough to diagnose the problem for me. Error code p2112 came over with a description about the throttle body actuator being stuck closed. They informed me they've seen this problem many times and it seems to be a common issue. It made sense to me because, leading up to this event, I had been experiencing a lagging throttle. It has happened to me twice more since this initial occurrence.

The contact owns a 2006 Ford Fusion. The contact stated that while driving approximately 25 mph, there was a sudden loss of power as the check charging system warning light illuminated. The vehicle was towed to a dealer where it was diagnosed that the pcm module, coils, spark plugs, and the intake manifold gasket needed to be replaced. The manufacturer was made aware of the failure. The vehicle was not repaired. The approximate failure and current mileage was 84,000.

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First incident when at a complete stop car physically jerking and jumping unless in park with engine light on. . Had Ford roadside to tow to fairway Ford kingsport where car was purchased where I was told it appeared to be the muffler and throttle body. When p/u car they had replaced cam solenoid switch and muffler. Car still had a loud vibration noise when on incline.

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On multiple occasions the car will just lose all throttle response, the car is still running, but will not accelerate. I have to find some place to pull over and shut the car off. Then restart the engine and then it will run good. The issue happens sometimes up six times in one day, and then you can go a week without an issue. I have seen this issue with speeds as low as 20 mph all the way up to 70 mph. From what I have read online it would appear to possibly be due to a defective throttle body. Apparently this throttle body uses a servo to open and close the butterfly that allows air into the intake manifold. I feel this could be a very dangerous problem especially if you are driving and it loses the ability to accelerate and you can not find a safe place to pull over to restart the car.