Ford Fusion spongy pedal problems

Filed Oct 5, 2026 · Brakes · MI

I am filing a formal safety complaint regarding an incomplete and dangerous repair under Ford Safety Recall 23S12 (the federal safety agency Campaign 23V162000) for my 2016 Ford Fusion SE AWD. Prior to the service, the vehicle suffered a massive brake fluid leak caused directly by the ruptured front brake hoses covered in this recall. This defect completely drained my master cylinder dry. While operating under these failed hydraulic conditions, the severe fluid loss and abnormal pedal pressure internally compromised the master cylinder seals and destroyed the internal vacuum diaphragm of the brake booster. I took the vehicle to Campbell Ford in Niles, MI to have the recall performed. The dealership replaced the brake hoses, but they flat-out refused to address or troubleshoot the dead power braking vacuum system and the rock-hard brake pedal. The service manager explicitly admitted to me that they did not run a single diagnostic test to rule out how the recall defect caused this booster failure. Instead, the dealership counter staff used the threat of an out-of-pocket diagnostic fee—which they knew I could not afford—to force me to sign a liability waiver and drive an actively unsafe, heavily compromised vehicle off their lot. The dealership fixed a leaking hose but left the catastrophic secondary damage caused by the recall completely unremedied, forcing a vulnerable driver recovering from [XXX] to operate a heavy vehicle with zero power brakes. I am requesting a federal review of this franchise's post-recall safety protocols and an immediate corporate escalation to resolve this vehicle's failure. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Aug 6, 2026 · Brakes · 149,000 miles · TX

The contact owns a 2012 Ford Fusion. The contact stated that while driving at an undisclosed speed, the brake pedal was depressed; however, the vehicle failed to stop as intended. The contact stated that the brake pedal was soft and spongy. The brake pedal was depressed to the floorboard before the vehicle stopped. No warning lights were illuminated. The vehicle was taken to an independent mechanic, and the contact was informed that the failure was not duplicated. The contact was informed that an inspection was completed, and the brake pads and rotors were in good working order. The contact stated that the failure had occurred two months after the brake pads and rotors were replaced by an independent mechanic. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 149,000.

Filed Apr 20, 2026 · Brakes · 110,000 miles · KY

The contact owns a 2009 Ford Fusion. The contact stated that the vehicle was taken to an independent mechanic for brake repairs, and after the repairs, the brake pedal felt spongy. The independent mechanic performed further inspections and diagnosed the vehicle with insufficient brake pressure due to a failure of the ABS hydraulic control unit. The manufacturer was notified of the failure. The contact related the failure to the federal safety agency Campaign Number: 19V904000 (Service Brakes, Hydraulic); however, the VIN was not included. The approximate failure mileage was 110,000.

Filed Mar 27, 2026 · Brakes, Driver assistance · CO

Complaint Description: I am filing a complaint regarding a severe brake assist failure in my 2014 Ford Fusion. The vehicle has experienced a repeated loss of brake assist, resulting in a hard brake pedal and increased stopping distance. Despite multiple visits to the dealership, only the vacuum pump was replaced, and the root cause was intally never fully diagnosed. Full diagnosis is still under dealersip review at Phil Long Ford of Denver. I am concerned that this is part of a larger, incomplete brake system failure. As several brake recalls have recently been fixed inclding replacing leaking brake lines and brake lights. While there are currently known recalls on certain Ford Fusion brake systems (such as brake hoses, brake lights etc), these recalls do not appear to cover critical components such as the vacuum pump, brake booster, hard brake lines, and camshaft. These omissions leave a gap in addressing a potentially life-threatening safety risk. The dealer’s incomplete diagnostic leaves me and others exposed to a dangerous failure. I urge the federal safety agency to open an investigation into these brake system components to ensure that a comprehensive recall is considered. The repeated failure, despite previous repair attempts, makes it imperative that all related brake components be thoroughly examined, as this is a life safety risk. Thank you for your prompt attention to this urgent matter.

Filed Oct 15, 2024 · Brakes · MO

Brake pedal randomly drops to floor, spongy brakes. Took to local dealer. My vin number is NOT part of recall. No parts are available.

Filed Sep 28, 2024 · Brakes · DC · crash

After activation of ABS brake system, brakes became "soft" and "spongy" with permanent increased braking time. As described in safety recall 19S54, this due to to a valve in the Hydraulic Control Unit (HCU) being stuck open. I received a letter from Ford Motor Company regarding this safety recall in 2011 informing of the defect and assuring "we will correct this condition." The vehicle was taken to Koons Ford (1051 E Broad St., Falls Church, VA, 22044; 703‑241‑7250) on 7/5/21 for repair. However, the HCU was not replaced, which appears to be the only remedy to this problem. Instead DOT 3 brake fluid was replaced with DOT 4 fluid, according to Koons Ford. However, after subsequent activation of the ABS brake system, the brakes became impaired again in the same way as before. I returned the car to Koons Ford on [XXX]. A "one-time" repair was performed pursuant to "customer satisfaction program" 21N11, as Ford acknowledged in a letter to dealers dated 12/7/21 that numerous customers were returning as the action prescribed in safety recall 19S54 did not repair the defective brakes. However, the HCU was not replaced. Service Advisor Kevin Lacki told me the HCU "passed" the inspection/diagnostic despite replication of the problem. I complained to Service Manager Rob Ryans who did nothing. I emailed the General Manager of the dealership twice, and he never responded. I called the manufacturer on [XXX] (case #[XXX]), but no action was taken. The problem of "soft" brakes and extended travel time quickly resurfaced and led to a vehicle accident in early 2023. The Ford Motor Company is employing a diagnostic that results in false "passes" for HCUs that should be replaced (and/or this dealership did not correctly perform the service actions). Even after "passing" Ford's diagnostic, the HCU valve(s) become stuck open after ABS activation. The safety recall should be investigated and the recall amended to replace faulty HCUs. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 55

Filed Aug 15, 2024 · Brakes · 130,000 miles · MI

The contact owns a 2012 Ford Fusion. The contact stated while driving at various speeds and depressing the brake pedal, the brake pedal felt spongy and required to be pushed down to the floorboard to stop the vehicle. The contact stated that the vehicle hesitated while responding, extending the braking distance. There was no warning light illuminated. The contact state that the failure occurred intermittently. The vehicle was taken to the dealer several times, but the failure could not be replicated. The contact stated that the failure had been recurring more increasingly. The vehicle was taken back to the dealer, where it was diagnosed and determined that the HCU had failed and needed to be replaced. The vehicle was not repaired. The contact related the failure to an unknown recall. The manufacturer was notified of the failure and a case was opened. The manufacturer referred the contact to the federal safety agency Hotline for assistance. The failure mileage was approximately 130,000.

Filed May 22, 2024 · Brakes · MS

Brakes are spongy and need to be pumped to stop vehicle in a timely manner. Brake fluid flush, brake pads and rotors did not solve the problem. The 2010 Ford Fusion SE has a recall dealing with a similar issue, but my specific VIN is not a part of the mass recall. No warning lamps or messages came on, but the brake pedal almost goes all the way to the floor to stop the vehicle. My safety and another cars safety were at risk because my brakes do not respond quickly enough to come to a complete stop if someone drives out in front of me or if I am simply coming to a stop at a red light or parking. I will be taking my car to the nearest Ford dealership in the next 2 days to have the braking system inspected and confirmed.

Filed May 12, 2024 · Brakes · 242,167 miles · FL

Abs module is not working. This is happening to not jusy my vehiclehowever many as I can see online and when ford is told something is wrong with it they say its not on the recall list. This is very dangerous as I almost got ibto a very bad accident because the brakes went to being ok to spongy and had to push to the floor to stop this car. Someone needs to fix this or it will end in someone getting seriously hurt or dying because of this situation.

Filed Jan 21, 2024 · Brakes · CT

The hydraulic control module/ABS control unit has malfunctioned, causing the brake pedal to become spongy. The pedal is not firm, and I need to press the brake pedal all the way down to get normal braking force. With normal functioning brakes, you press the pedal down 25%; however, I must press down 75% until I even begin feeling the car slow down. There were no warning lights, and this problem has existed for two years. I have replaced the brakes and bled the fluid multiple times, but the problem persists. I have had very close calls with other drivers where I have not had enough time to stop due to having to press the brake pedal all the way down. This problem is constant and occurs whether I drive in the city or on the highway. The city is especially dangerous due to frequently having to stop for traffic signals or suddenly stopping for pedestrians or other vehicles on the roadway. I have not had this issue officially diagnosed by a dealership; however, my vehicle is available for inspection. I have experienced symptoms similar to those of many peers with the same vehicle. My peers have changed the master cylinder, brakes, and flushed brake fluid many times, yet the problem has persisted and has been diagnosed as a hydraulic control module/ABS control unit issue that requires replacing the unit. A recall was issued for select 2010 Ford Fusions regarding this issue; however, after checking on the federal safety agency and Ford websites, my vehicle is not eligible for a recall despite experiencing similar issues. I hope by bringing this to your attention there can be a new recall issued to encompass all 2010 Ford fusions and associated models experiencing the same issues, as having functional brakes is extremely important for not only the safety of the vehicle occupants but also for others using the roadway. I hope the federal safety agency, in collaboration with Ford, will work in the best interest of the public's safety to swiftly address this issue before any unfortunate accidents occur.