Ford Fusion stalling problems

Filed Sep 30, 2026 · Engine · NC

Capital Ford of Wilmington diagnosed my vehicle with coolant intrusion into cylinder 2, accompanied by diagnostic trouble codes P0302 and P0316, after check engine light came on. I have been advised that the vehicle requires a complete engine replacement, with an estimated cost of $13,180.89. The vehicle has experienced sputtering and hesitation, creating concern that it could lose power or stall. These symptoms are concerning. After researching this issue, I have learned that coolant intrusion is a documented problem associated with certain Ford vehicles equipped with the 1.5L EcoBoost engine produced during the 2017–2019 period. Ford has addressed this issue through Technical Service Bulletins and Customer Satisfaction Program 21N12. I contacted Ford and was told that my VIN is not covered under the Customer Satisfaction Program. When asked why mine was not covered but other were , Ford stated that even if it is the same issue that is being recalled if my VIN is not flagged it will not be covered for any recall or assistance.I called Ford when I first purchase vehicle and asked about this recall and was told if I didn't have anything wrong with my car and no engine lights that my car was fine and to bring it in if I have any issues.

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 21, 2026 · Electrical, Fuel system · LA

I am the original single owner of a 2019, paid-off, gas Fusion with less than 54,000 miles, a spotless maintenance record, and no accident history. The vehicle suffered a sudden, instantaneous total loss of motive power. The loss of electric power steering assist and loss of power brake assist while driving through a live intersection with no warning lights or prior engine shuddering nearly caused a severe, life-threatening, or even fatal collision. The vehicle was removed from the intersection by physically pushing it with the assistance of other passing motorists and local police. I immediately called and requested towing services through the manufacturer. Services arrived 2 hours later. They started the car with no issue and drove it onto the tow truck. No engine lights or warning lights were present; the vehicle did not stutter or shake, and the vehicle had a 1/4 tank of gasoline. The vehicle was delivered directly to the Dealership. After it stalled and once it was removed from the intersection, no attempt was made to restart the vehicle until the towing service arrived. The dealership has had the vehicle for 2 weeks and claims they cannot diagnose the cause; there are no active diagnostic codes, and they have not been able to replicate the failure regarding this potentially fatal electrical shutdown. It is completely unacceptable and dangerously irresponsible for a dealership to hold a vehicle for 2 weeks, then suggest "picking it up, add some gas" simply because they haven't found any issues and "it should be fine." I cannot, in good conscience and out of protection of myself, my family, and other motorists, continue operating a vehicle that exhibits life-threatening intermittent failures.

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 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 15, 2026 · Engine · MI

COMPONENT THAT FAILED: The engine cooling fan on my 2020 Ford Fusion SEL (1.5L, non-hybrid) became inoperable and blew three fuses. With the fans not operating, the engine overheated, destroying the head gasket and engine, requiring complete replacement. Failure occurred 07/08/2026 at 49,118 miles. WARNING SYMPTOMS: The A/C began blowing warm air roughly 2 days earlier. The engine temperature lamp illuminated on 07/08/2026 — the first and only time it ever came on. No prior overheating, no coolant loss, no leaks, no other alert. I stopped driving immediately on that single warning and had the vehicle towed. SAFETY RISK: A cooling fan failure progressing to engine destruction risks overheating, loss of motive power, and stalling in traffic or at highway speed. I stopped safely; a driver getting this same lone warning on a freeway would face a serious hazard with no notice. The vehicle's protections did not prevent a low-cost part from destroying the powertrain, and the sole warning came immediately before catastrophic damage. CONFIRMED BY INDEPENDENT SERVICE CENTERS: Yes. A certified technician at a licensed independent shop found the cooling fan assembly inoperable and identified it as the cause of both the A/C failure and the temperature warning, noting these vehicles are known to fail head gaskets this way. A second licensed engine shop documented the sequence: the electric cooling fan failed, which blew three fuses, causing an overheat condition that caused engine failure. Written findings, inspection reports, and invoices retained. MANUFACTURER INSPECTION: None. Ford declined to consider assistance unless a Ford technician inspected the vehicle, by which time it was already at an independent shop mid-repair. No police or insurance inspection. MANUFACTURER AWARENESS: Ford SSM 48659 covers 2019-2020 Fusion/MKZ non-hybrids with cooling fans inoperative due to open fuses F59, F60, F63, causing engine overheat or lack of A/C cooling.

Filed Jul 31, 2026 · Engine · FL

The contact owns a 2013 Ford Fusion. The contact stated that while driving at an undisclosed speed, the low coolant warning light illuminated, and the vehicle stalled. The failure was a recurring failure. The contact associated the failure with the federal safety agency Campaign Number: 12V551000 (Engine and Engine Cooling); however, the VIN was not included. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was unknown.

Filed Jul 9, 2026 · Engine, Fuel system · MI

Vehicle makes strange sounds from the fuel fill inlet and proceeds to stall shortly after while driving and most of the times fails to restart based on my own research it looks like purge valve issues My safety was put at risk by almost being rear ended multiple times from stalling on the expressway and red lights The problem has not been reproduced yet by the dealer it will be looked at on 07/15/26 The component has not been inspected yet The check engine light illuminated when the issue started

Filed Jul 6, 2026 · Engine · 87,127 miles · CO

The contact owns a 2020 Ford Fusion. The contact stated that while driving at an undisclosed speed, the engine stalled. No warning lights illuminated. The vehicle was able to restart after several attempts. The vehicle was taken to the dealer, where it was diagnosed with coolant intrusion into cylinders 3 and 4. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 87,127.

Filed Jul 1, 2026 · Engine · ID

My 2019 Ford Fusion 2.0L EcoBoost (89,000 miles) experienced a sudden, severe engine malfunction due to a known manufacturing defect. The vehicle exhibited severe engine shuddering and a harsh cold-start misfire upon ignition. A diagnostic scan revealed trouble codes P0316 (Misfire on Startup), P0302 (Cylinder 2 Misfire), and P0304 (Cylinder 4 Misfire). A mechanic verified that these codes are the result of internal coolant intrusion into the engine cylinders, exactly as documented in Ford Technical Service Bulletin TSB 19-2346. The structural design flaw in the engine block allows engine coolant to breach the cylinder head gasket area and pool inside the combustion chambers. This presents a critical safety hazard: the vehicle is at risk of sudden engine stalling while driving on public roads, a complete loss of motive power in traffic, and potential engine hydro-lock, which can cause catastrophic mechanical failure or an engine compartment fire. Ford is refusing to address this safety defect outside of warranty, leaving a hazardous vehicle on the road.