2020 Ford Fusion fuel system problems

Filed Oct 26, 2026 · Engine, Fuel system · MI

COMPONENT/SYSTEM: Gasoline vapor entering the occupied passenger cabin through the HVAC vents during and after rain with the A/C or heat on. Root cause unidentified, not because it cannot be found, but because Ford Motor Company has not once tested the vehicle under the condition in which the defect occurs, and has refused in writing to assign an engineer who would. Suspected fuel system / evaporative emissions / cowl-to-HVAC intake pathway. Vehicle available to the federal safety agency for inspection on request. SAFETY RISK: The driver and passengers breathe gasoline vapor inside a closed, moving vehicle. Fuel vapor in an occupied cabin is an inhalation hazard and an ignition hazard. The owner drives with the windows open to vent it. Ford’s own agent acknowledged in writing on 09/24/2026: “I understand that your vehicle currently has a gas odor and you do not feel safe driving it.” Ford has since returned the vehicle to the owner unrepaired four times, has never stated it is safe to drive, and has stated in writing that it is closing the case. The vehicle is on the road today with the defect present. If this condition exists on other Fusions, those owners cannot rely on Ford’s dealer network to detect it, because Ford’s diagnostic procedure, as applied four times to this vehicle, does not test for it. REPRODUCED/CONFIRMED BY DEALER: YES, BY FORD’S OWN DEALER, IN WRITING. Serra Ford Farmington Hills, authorized Ford dealer, repair order [XXX], opened 07/17/2026, 45,535 miles: “CUSTOMER STATES GAS SMELL FROM AC DUCT WHEN AC IS BLOWING FULL BLAST, VERIFIED ON DRIVE.” The advisor drove the vehicle and smelled it. First reported to the same dealer 06/23/2026, RO [XXX]: gas smell inside the cabin after rain, from the AC/heat. Ford Motor Company Customer Relations supervisor Juan Garza confirmed in writing on 10/21/2026: “I reviewed the July 17 repair order language stating that the concern was ‘verified on drive.’” The next day, 10/22/2026, the same supervisor recharacterized the same INFORMATION REDACTED PURSUANT TO THE FREEDOM OF I

Filed Mar 19, 2026 · Body, Electrical · DE · fire · 1 injury

I am reporting a life-threatening incident involving my 2020 Ford Fusion PHEV. On December 5, 2025, while my wife was driving on a public street, the vehicle suffered a sudden, complete engine failure followed by smoke and fire originating from the high-voltage battery pack in the trunk. There were no prior warning signs or dashboard alerts before the incident. This vehicle was sold via IAAI auction in September 2023 without disclosing the active, critical safety recall (the federal safety agency 23V440 / Ford 23S33) issued in June 2023. This non-disclosure placed my family in extreme danger. When the fire started, my wife was in a state of panic. I arrived at the scene before emergency services. Being a technician, I performed a high-risk manual extraction of the burning battery pack to prevent the entire vehicle and the surrounding residential area from a potential explosion. I risked electrocution and toxic chemical exposure to save lives. The damaged battery pack is currently preserved and available for professional inspection upon request. As a result of the fire and exposure to extinguisher chemicals, I suffered respiratory distress and asthma-like symptoms for several days. I have contacted Ford Motor Company through official channels and documented all interactions. Ford representatives stated that they 'only assist customers in the United States' and local representatives in [XXX] have officially refused to provide the remedy, stating they are not authorized or equipped for this specific recall. I am now left with a charred, unusable vehicle. I demand a full investigation into the failure of the recall remedy process and manufacturer liability for these life-threatening damages. ( Form fields about my location are place holders. Contact me in [XXX] (Country) at [XXX] / [XXX] ]. I hope you do don't ignore our lives due to geography. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Mar 17, 2026 · Engine, Fuel system · LA

purge solenoid unplugged, several times for years, which causes the vehicle not to start up after getting fuel. Check engine light come on often due to this. When I bring vehicle to Mecanic shop they plug it right back. P0443 evap purge control valve “a” circuit

Filed Feb 26, 2026 · Fuel system · TX

I have a check engine light on due to an issue in the emissions system. The issue is that the purge valve is stuck open. I know that this is an issue that you had a recall on for older models of the ford focus for this same reason. All the systems of a stuck purge valve are the issues I am having with the vehicle.

Filed Feb 13, 2026 · Electrical, Fuel system · DC · fire

"The incident occurred immediately after shifting the vehicle into reverse and starting to move. The engine suddenly shut down with a 'System Performance' alert, and cooling fans engaged at maximum speed. Moments later, a thermal runaway event began in the high-voltage Li-ion battery pack, leading to a catastrophic fire. This is directly related to Recall 23V440 / 23S33 (BECM failure). The fire was extinguished by the local fire department in Telavi, Georgia (Country)."

Filed Dec 19, 2025 · Engine, Fuel system · TN

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.

Filed Dec 17, 2025 · Engine, Fuel system · WA

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!

Filed Nov 9, 2025 · Fuel system · IL

Check engine light keeps coming on saying evap emissions. Have replaced purge valve, gas tank inlet and solenoid. This is the 6th time for check engine light

Filed Sep 29, 2025 · Fuel system · IL

Previously reported as a fuel pump issue, incorrect. The mechanic was incorrect. The fuel injectors failed releasing fuel into the engine and the entire system. High risk of fire.

Filed Sep 15, 2025 · Fuel system · IL

Fuel pump failure. Vehicle is emitting gas from the exhaust system in the back. Not processing fuel as it should. High safety risk.