Electrical System Problems of Ford Fusion Hybrid - part 1

National highway traffic safety administration office of defects investigation / vehicle safety hotline 1200 new jersey avenue se west building washington, DC 20590 vehicle safety complaint 2019 Ford Fusion Hybrid Ford recall 23s33 / NHTSA recall 23v440/June 16, 2023 to whom it may concern: I am submitting this correspondence to formally document a potentially serious safety concern involving my 2019 Ford Fusion Hybrid, which is subject to Ford recall 23s33 / NHTSA recall 23v440. I have made multiple attempts to have the outstanding recall completed through autonation Ford wolfchase, located at 7925 stage road, bartlett, tennessee 38133. During previous attempts to schedule the recall repair, I was advised that parts would need to be ordered and that the dealership might need to retain my vehicle for more than two weeks. I was told I would be contacted when the required parts became available. However, I did not receive the promised notification that the parts had arrived or that the repair could be completed. During this period, my vehicle displayed an “extreme overheated” warning during normal operation. I reported this condition to the dealership. On [xxx], I brought the vehicle to autonation Ford wolfchase after experiencing an additional serious condition involving the 12-volt battery and an extremely strong sulfur/rotten-egg odor. The odor was severe enough to be readily noticed by dealership personnel and mechanics when the vehicle arrived. Their reaction to the odor caused me additional concern about whether the vehicle had been safe to operate. I am concerned that I was operating a vehicle with an unresolved safety recall while simultaneously experiencing overheating warnings and, ultimately, an abnormal battery/charging condition accompanied by a severe sulfur odor. I understand that a technical inspection is necessary to establish whether these conditions were caused by or related to recall 23s33/23v440 I have mailed out a certified letter information redacted pursuant to the freedom of informati.

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While driving my 2012 Ford Fusion Hybrid (VIN: [xxx]), the braking system suddenly failed. When applying the brake pedal, there was completely zero brake resistance, and the vehicle failed to engage proper braking power, creating an extremely hazardous driving condition. The vehicle was inspected by a certified Ford dealership (lithia), which officially documented that the vehicle is "unsafe to drive due to having no brake resistance. " the diagnostics confirmed that the abs hydraulic control unit (hcu), the abs module, and the brake master cylinder have failed and require total replacement. The dealership also noted that the necessary braking parts are currently completely unavailable (backordered/no parts available). This is the exact same safety defect covered under Ford's previous safety recall 19s54 (NHTSA campaign 19v904) for older fusion models. However, the recall was never expanded to include the 2012 models, despite them using the same problematic braking infrastructure and experiencing identical catastrophic failures. Nhtsa needs to investigate and force Ford to expand the recall to 2011-2012 models before this braking defect causes fatal accidents. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

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Charge circuit condition indicator light this is defective electrical system that left not corrected there is a possibility of an electrical fire. Three indicator lights units have been installed on this vehicle, a 2019 Ford fusion energi ( known as a plug in hybrid) all three indicator charge level lights have burn out within a warranty period of operation and Ford will not acknowledge faulty hardware have been installed in this and other vehicles’. Ford refuses to acknowledge warranty replacement or quality issues with this device. This is a plug in hybrid system using a high voltage battery.

I own a 2010 Ford Fusion Hybrid and am reporting a recurring and serious braking problem. On xxx, while driving to pick up my mom and my [xxx] son, I pressed the brake pedal to stop, but the vehicle did not stop normally. I repeatedly tried to brake, but the vehicle took much longer to stop than it should have. The brake pedal became spongy and did not have normal resistance. The brake, abs, and advancetrac warning lights appeared. The vehicle’s computer/system was reset afterward, and the vehicle drove normally for several days. On xxx, the same braking problem happened again while I was driving to go pick up my [xxx] son from school. The brake pedal became spongy, and repeatedly pumping the brakes did not properly stop the vehicle. This time I had to use the emergency/parking brake to help bring the vehicle to a stop. The same brake, abs, and advancetrac warning lights appeared. After this incident, the rear brakes were replaced and a new abs anti-lock brake pump (part number 9e58-2c555-af) was installed. The computer/system was also reset again. On xxx, the brake, abs, and advancetrac warning lights came back on again despite the new brake components and computer reset. The mechanic who performed the repairs has been unable to determine the cause, so the vehicle is being taken to another repair shop for further diagnosis. I am concerned that this may be a safety defect involving the braking/abs system of the 2010 Ford Fusion Hybrid. The vehicle has experienced an actual loss of braking ability, including an incident where I had to use the emergency/parking brake to stop. I am requesting that NHTSA investigate this issue. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

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The car is suffering random shutdown and intermittent times. The battery is no longer holding a charge and when it shuts down this places me at extreme risk. Ford is unable to fix it so this is no longer happening without replacing the high voltage battery - battery from Ford alone is 11k. I cannot be the only one who is dealing with this car doing this.

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Ford fusion energi battery failure. Dealership wouldn't inspect the battery and kept replacing the battery control module. The replacement part kept failing under warranty and then the dealership quoted me $20,000 for the hybrid battery. They have replaced the bcm twice and error code p0dc9 keeps appearing. The ev range drops to zero randomly or gains range while parked and not plugged in. Dealership doesn't know what's happening even after paying money for diagnostics.

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There have been many recalls on the 2010 Ford Fusion Hybrid, according to Ford mine has already had the repairs done yet the issues I’ve been having all match recalls. I’ve had issues with my passenger seat, the air bag system light is always on and the seat controls no longer work. The clockspring system is pure trash, there is no reason I’ve had to replace it twice now in the 2 months I’ve had this car. My abs system keeps going in and out and says service advancetrac system. My hybrid battery rarely goes into hybrid anymore causing my mpg to drop. There were a few other things but that’s what’s coming out mind now.

I am filing a complaint regarding Ford safety recall 23s33 (NHTSA campaign 23v440) for my 2020 Ford fusion energi. I brought my freshly purchased vehicle to my local authorized dealer, sheehy Ford, to fix the high-voltage battery replacement recall. The dealership told me they had to order the part before they could schedule the repair. They have since stated that Ford corporate is experiencing low stock and is not allocating the necessary remedy parts to the dealer network, and referred me to call Ford corporate. Purchased this vehicle on 21 March 2026; took it to dealer to get the recall fixed on 23 March. Dealer said it would be delayed due to the recall being started in [xxx] (where the vehicle was shipped from via carmax, and sold to me in [xxx]). After a month, the dealer opened a case with Ford corporate (xxx). I called to check status, was put on hold for 20 minutes, then transferred, and was then disconnected. It has been 4 months since I took it in to get the recall repaired. The manufacturer is failing to provide a timely safety remedy as required by federal law, leaving me to drive a vehicle with a documented risk of fire and sudden loss of motive power. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

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I am submitting this complaint regarding an unrepaired safety recall on my 2016 Ford fusion, Ford recall 25sa9 / NHTSA recall 25v695, involving the rear-view camera. The recall concerns a condition where the rear-view camera may display a blank or distorted image when the vehicle is placed in reverse. This can reduce the driver's ability to see what is behind the vehicle and increase the risk of a crash. The recall was issued in October 2025. I have been waiting for the recall remedy to become available, but Ford and the dealership have been unable to complete the repair because the necessary parts are not available. As of August 11, 2026, my vehicle's NHTSA recall status still states: "recall incomplete, remedy not yet available. " this means that approximately 10 months after the recall was issued, I still do not have access to the recall repair for a known safety defect. I understand that parts shortages can occur; however, I am concerned that such a significant amount of time has passed without Ford providing a remedy. The recall information indicates that the remedy was expected to become available, yet my vehicle remains unrepaired. I am requesting that NHTSA review Ford's handling of this recall and determine: why the recall remedy remains unavailable approximately 10 months after the recall was issued. When Ford expects the required repair parts to actually become available. Whether Ford is taking adequate steps to provide affected vehicle owners with a timely and effective remedy. Whether Ford has provided an adequate interim solution for owners while they wait for the repair. I have contacted the dealership regarding the recall and have been advised that they cannot complete the repair because the necessary parts are unavailable. I am requesting NHTSA's assistance and review because this is a safety recall that remains unresolved many months after being issued. Vehicle: 2016 Ford fusion manufacturer recall: 25sa9 NHTSA recall: 25v695 defect: re.

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I am reporting a serious safety issue with my 2018 Ford Fusion Hybrid se that affects the braking system and related electronics: 1. The abs stopped functioning previously. 2. Recently, the car displayed a “brake malfunction” warning for the first time, which appears when making sharp turns. 3. The tpms (tire pressure monitoring system) stopped working some time ago. These issues are extremely dangerous. The electronic brake booster and abs module are critical for safe braking, especially in emergency situations. With the abs and brake assist compromised, the pedal can suddenly become rock hard or soft, stopping distance increases dramatically, and traction control/abs is unavailable during hard braking. I am concerned this is a systemic issue with the 2018 Ford Fusion Hybrid se braking system and not isolated to my vehicle. This failure could put drivers, passengers, and others on the road at serious risk. I request that NHTSA investigate this issue for potential recall action to protect the safety of drivers nationwide.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v44000 (electrical system); however, the part to do the recall repair was unavailable. The contact stated that the vehicle was taken to the dealer where it was confirmed that the hv battery needed to be replaced. The contact was informed that the hv battery was ordered on June 6,2025. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact was informed that parts were on back order and there was no delivery date available. The contact had not experienced a failure. Parts distribution disconnect.

The contact's granddaughter owned a 2013 Ford Fusion Hybrid. The contact stated that while her granddaughter was driving at an undisclosed speed, the driver looked in the rearview mirror and noticed that there was black smoke coming from the rear seats of the vehicle. The contact stated that the driver's sons were in car seats in the rear seats of the vehicle. The driver immediately pulled over to the side of the road, exited the vehicle, and took her sons out of the vehicle. The contact stated that the entire vehicle then caught on fire. The contact stated that the driver's side of the vehicle was more burned than the rest of the vehicle. The fire was extinguished by the fire department, who informed the contact's granddaughter that the fire might have originated from the trunk of the vehicle. It was unknown whether a police report or a fire department report was filed. The contact stated that the vehicle was towed and could be totaled. The driver's mother transported the driver and her sons to the emergency room due to smoke inhalation. It was unknown whether injuries were sustained. The dealer and the manufacturer were not notified of the failure. The failure mileage was unknown.

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I am filing this complaint concerning my 2020 Ford fusion energi and Ford safety recall 23s33 / NHTSA recall 23v440 involving the high-voltage battery. Ford's recall notice states that the battery energy control module may become damaged due to excess voltage and current flow caused by a current interrupt device activation in one or more high-voltage battery cells. Ford states that this can result in loss of motive power or a vehicle fire. My vehicle has been subjected to the recall remedy/interim work and I cannot use its plug-in charging capability. I purchased this vehicle specifically as a plug-in hybrid. Ford's may 2026 recall notice states that Ford authorized dealers to replace the high-voltage battery free of charge and that the repair will restore plug-in charging functionality. However, I have subsequently been informed that a replacement battery may not actually be available for my vehicle until approximately xxx, and I have been told that even that estimated timeframe is not guaranteed. I purchased this vehicle used at approximately 37,000 miles and it currently has only approximately 43,705 miles. I have therefore driven it only approximately 6,705 miles since purchasing it. My concern is that Ford acknowledges a safety-related high-voltage battery defect and has restricted the plug-in capability of the vehicle, yet I may potentially have to wait until late 2027 or longer for the replacement battery that restores the vehicle's intended functionality. I am requesting that NHTSA review Ford's administration of recall 23s33 as it relates to the availability and timeliness of the permanent high-voltage-battery remedy and determine whether owners such as myself are receiving a safe, free and effective recall remedy within an appropriate period. I was working in [xxx] and did not receive recall information at my [xxx] address I am back in [xxx]. I want Ford to buy back the vehicle based on the letter sent. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

My car dies and needs jumped everytime I shut it off. There's an odd clicking sound coming from the front floor of the trunk behind the drivers side back seat. This has been happening for 2 days now. I think I can smell something burning, but I've only had that smell once today.

The factory-installed rearview backup camera on my 2013 Ford fusion fails intermittently. When shifting into reverse, the display screen frequently goes black, shows a distorted or flickering image with multicolored lines, or displays an error message stating the camera is unavailable. The failure is unpredictable but occurs more often in hot weather or after rain, suggesting a hardware defect. The component that has failed is the rearview camera system, likely the camera module itself, which is available for inspection. This malfunction creates a significant safety hazard by eliminating rear visibility, substantially increasing the risk of a back-over collision with pedestrians, children, or other objects. The failure to display a rearview image is a non-compliance with federal motor vehicle safety standard no. 111. The problem has not been confirmed by a dealer due to its intermittent nature, making it difficult to reproduce on demand. The vehicle has not been inspected by the manufacturer or other parties regarding this issue. The symptoms first appeared several months ago and have become progressively more frequent. The primary warnings are the on-screen error messages and the loss of the video feed itself.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system); however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system); however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

The contact owns a 2016 Ford fusion energi. The contact stated while reversing at 5 mph, the rearview camera failed to respond. There were no warning lights illuminated; however, there was a message displayed that the rearview camera would stop working while in reverse, and to please contact the dealer if the camera failed to operate as needed. The failure was intermittent. The vehicle was not taken to be diagnosed or repaired. The contact stated the radio intermittently failed to operate as needed. The dealer was not made aware of the failure. The manufacturer was not made aware of the failure. The failure mileage was approximately 105,000.

The contact owns a 2019 Ford fusion energi. The contact received advance notice notification from the dealer that a failure with the charging system might cause the vehicle to catch on fire however, the part to repair the charging system was not available. The dealer was contacted; however, the vehicle was not repaired. The contact had not experienced a failure. The manufacturer was made aware of the failure and referred the contact to the nhsta hotline for assistance. The failure mileage was approximately 43,000.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The dealer was made aware of the issue. The manufacturer was made aware of the issue and confirmed that parts were not yet available. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The dealer was made aware of the issue and confirmed that parts were not yet available. The manufacturer was made aware of the issue and confirmed that parts were not yet available. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. The local dealer was not contacted. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not available. The local dealer was contacted, and it was confirmed that the part was not available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The dealer was contacted and confirmed that parts were not yet available. The manufacturer was made aware of the issue and informed the contact that a second notice would be mailed when the part was available. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The contact stated while driving 10 mph at night, the message "system fault" and "safely stop" were displayed, and the vehicle lost motive power. The contact was able to pull to the side of the road. A message advising to shift to neutral and restart the vehicle was displayed. The contact shifted into neutral(n), but the vehicle failed to restart and was in accessory mode. The message "shutting system down to save battery " was displayed, and the vehicle shut off. There was no electrical power. The vehicle was towed to the dealer to be diagnosed. The vehicle was not diagnosed or repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the failure and offered to partially reimburse the expenses of a rental. The failure mileage was approximately 46,000. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The dealer was made aware of the issue and confirmed that parts were not yet available. The manufacturer was made aware of the issue and confirmed that parts were not yet available. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

The contact owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system) however, the part to do the recall repair was not yet available. The contact stated the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated while driving 45 mph, the vehicle temporary lost motive power and jerked. The check engine warning light was illuminated. The vehicle was taken to the dealer and the contact was informed the failure was related to the recall. The vehicle was not repaired because parts were not yet available. The manufacturer was made aware of the failure but provided no assistance. The approximate failure mileage was 44,000.

The contact owns a 2019 Ford fusion energi. The contact stated that the battery was inoperable. The contact was unable to use the rapid charger. The contact was unable to charge the vehicle. The contact stated that the heated seats were inoperable. The check engine warning light was illuminated. The contact was concerned about using the vehicle. The contact received notification of NHTSA campaign number: 23v440000 (electrical system); however, the part to do the recall repair was not yet available. The local dealer was contacted. The vehicle was not diagnosed or repaired. The dealer informed the contact not to use the rapid charger. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The failure mileage was approximately 30,000. Parts distribution disconnect.

The contact owns a 2013 Ford Fusion Hybrid. The contact stated that while sitting in the passenger seat as their husband was driving through a fast food drive-through and attempting to make a left turn the power steering suddenly failed. The dashboard was illuminated with several different lights, meanings unknown, however, there were no warning lights before the failure occurred. The driver had used an excessive amount of force to pull to the side where he turned the vehicle off and then restarted it to regain proper function. The failure persisted. The vehicle was taken to an independent mechanic where it was diagnosed that the electrical power assist system failed. The independent mechanic informed them that the failure was related to NHTSA campaign number: 15v250000 (steering) and referred them to Ford. The dealer was contacted and informed that the VIN was not included in the NHTSA campaign number: 15v250000 (steering) but was included in NHTSA campaign numbers: 22v413000 (power train) and 20v331000 (locks, latches ) . The vehicle had not been repaired. The manufacturer was made aware of the failure and confirmed the VIN was not included in NHTSA campaign number: 15v250000 (steering) then referred them to NHTSA. The approximate failure mileage was unknown.

The contact's wife owns a 2019 Ford fusion energi. The contact received notification of NHTSA campaign number: 23v440000 (electrical system); however, the part to do the recall repair was not yet available. The contact stated that while starting the vehicle, the instrument cluster and the infotainment system remained off. The contact stated that the failure had reoccurred. The contact stated that he turned off and restarted the vehicle, until the vehicle responded as needed. The local dealer was contacted. The vehicle was not diagnosed or repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the failure. The failure mileage was approximately 25,000. VIN tool confirms parts not available.