Ford Fusion misfire problems

Filed Oct 26, 2026 · Engine · 138,000 miles · MI

The contact owns a 2018 Ford Fusion. The contact stated that there was an abnormal sound coming from the rear of the vehicle. In addition, the engine made a bubbling sound after turning off the vehicle. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, where an engine misfire was diagnosed, and a fuel odor was detected. The mechanic determined that the engine had failed and needed to be replaced. The failure mileage was approximately 138,000.

Filed Oct 23, 2026 · Engine · IA

2016 Ford Fusion 1.5L Ecoboost engine w/approx. 88,000 miles was just purchased from private owner on 10/7/26. On 10/17/26 the check engine light came on and showed problem with cylinder 1 and 4. Car was running ruff, misfiring, losing power. Safety issue for losing power on highway. New spark plugs installed and cylinder 1 and 4 replaced. Replaced cylinder 4 twice but this did not work. Local auto shop scoped car as well as did pressure tests. Coolant Intrusion into cylinders. Defective head gasket and design of engine. Car needs engine replaced. Coolant intrusion with defect of the engine should be a recall from Ford.

Filed Oct 21, 2026 · Engine · MD

Ford Ecoboost coolant intrusion. Loss of coolant without noticeable leaks. Loss of power while experiencing cylinder misfire. After cool-down, engine runs rough with white tailpipe smoke and generates check engine light for cylinder misfire.

Filed Sep 28, 2026 · Engine · 72,000 miles · OH

The contact's brother owns a 2020 Ford Fusion. The contact stated that while the owner was driving 35 MPH, the engine overheated and there was misfire coming from the engine. The check engine warning light illuminated, and there was fluid leaking into the engine. An independent mechanic was contacted by phone. The vehicle was taken to the independent mechanic and was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The contact was informed that the failure was a known failure with the vehicle. In addition, the contact was informed that the failure was due to the manufacturing design of the engine. The manufacturer was contacted by phone and a case was filed. The failure mileage was approximately 72,000.

Filed Sep 25, 2026 · Engine · OH

My 2018 Ford Fusion Titanium FWD (VIN: [XXX]) suffered a catastrophic engine failure while driving, causing sudden vehicle overheating, severe engine misfires, and a dangerous loss of power on the roadway.A certified Ford dealership inspection (Invoice #XXX) confirmed that the vehicle has a textbook manufacturing flaw known as EcoBoost coolant intrusion. A pressure test showed an immediate 5 PSI drop within 10 minutes, and a borescope confirmed that engine coolant is actively leaking across the block interface and pooling directly inside the engine cylinders (cylinders 2 and 3).This is a known, widespread structural engineering defect in Ford's block casting that creates a severe, sudden safety hazard by causing vehicle stalling and clouding exhaust smoke while operating at highway speeds. The vehicle is now entirely unsafe to drive and requires a full engine block replacement. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Sep 17, 2026 · Engine · OK

Exhibited signs of a coolant leak followed by throwing a code about cylinder 4 misfiring. Took my car to the dealer who confirmed that there is coolant leaking into cylinder 4, and it is similar to other defects found in many 1.5 liter ecoboost engines from this model line. Was told that my VIN did not qualify for the recall that is only for the ecoboost 2.0 liter engines even though they have the same defect.

Filed Sep 14, 2026 · Engine · MI

I am submitting this complaint regarding a serious engine failure and safety issue involving my 2017 Ford Fusion equipped with the 1.5L EcoBoost engine. At approximately 79,000 miles, my vehicle experienced a coolant intrusion failure. While driving, the engine suddenly stalled in the middle of an intersection, leaving me stranded in traffic and at risk of being rear-ended by approaching vehicles. I was able to restart the vehicle and move out of the intersection, but the exhaust then produced a very large, thick cloud of white smoke. The amount of smoke could have significantly reduced visibility for other drivers and created an additional safety hazard. I took the vehicle to a Ford dealership, where I was told the engine had coolant intrusion and needed to be replaced. I was also told this is a common problem with Ford EcoBoost engines, including the 1.5L, 2.0L, and 2.3L engines. My concern is not only the cost of the repair, but the serious safety risk. Coolant intrusion can cause misfires, excessive white smoke, engine damage, and eventual engine failure. A sudden loss of power while driving can create a serious crash hazard, as happened to me. I am concerned Ford has known about this recurring problem for years yet has continued using these engines in vehicles such as the Fusion, Escape, and Lincoln MKZ without adequately addressing the issue. I request that the federal safety agency investigate coolant intrusion affecting Ford EcoBoost engines and determine whether a safety defect exists that warrants a recall. I also believe affected owners should receive reimbursement for engine replacement costs when the failure is caused by this defect. My experience demonstrates that this is more than a normal maintenance issue. An engine that can suddenly stall in traffic and produce a large cloud of white smoke without warning poses a significant safety risk to vehicle occupants and other motorists.

Filed Sep 9, 2026 · Engine · MO

It all started with a cylinder 3 misfire warning code, spark plugs replaced, coils replaced. Then a coolant leak. No obvious signs of a leak no cracked tubing no puddles. Just coolant leaking. Was informed I have a coolant leak intrusion and need a new engine block. I still owe $14k on this vehicle and am past my warranty. This repair is going to cost $12k. Researched and found out this is a problem for these vehicles that ford had an engineering problem with these engines.

Filed Sep 8, 2026 · Brakes, Engine · FL · crash

Year/Make/Model: 2015 Ford Fusion Engine Type: 1.5L EcoBoost 4-Cylinder Description of Safety Flaw and Incident: My vehicle is experiencing severe overheating and internal engine fluid loss due to the widely documented Ford EcoBoost coolant intrusion defect. The vehicle routinely runs hot, losing coolant rapidly with no external signs of a visible hose or radiator leak as well as failure of the brake lighting stop bumper and purge valve connecting to the gasline after fueling. This issue causes the vehicle to rapidly overheat while in motion, forcing sudden loss of engine power (limp mode) during highway driving. Car not properly cranking after fueling and brake light continuously being on even when brakes not being pressed. This unexpected drop in speed creates an immediate crash hazard for myself and surrounding traffic. Coolant entering the combustion chamber also fouls the spark plugs, causing severe engine stalling, rough idling, and misfires. I've spent several dollars fixing these malfunctions that have continuously persist. Ford Motor Company has historically been aware of this structural defect involving coolant leaking across the cylinder bore walls, yet failed to issue a comprehensive safety recall for 2015 models. I am filing this complaint to urge the federal safety agency to open a formal defect investigation and mandate a safety recall, as this component failure leaves drivers stranded in hazardous traffic situations.

Filed Aug 26, 2026 · Engine · NJ

We have coolant intrusion in cylinder 2 of our engine. This can cause highway failure of engine cuts out, car runs rough and it can become a fire hazard. We paid for a diagnostics through a ford dealer. Who we uses all the time for our warranty needs. We noticed car was starting to run rough and check engine light came on 8/5/26