Ford Fusion 2020 — Reported problems

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.

2020 Fusion SEL with 41,000 miles. While driving at 65 mph with adaptive cruise control engaged, the vehicle suddenly jerked on two separate occasions during a three-hour drive.

I recently acquired this vehicle from a dealer after the previous owner traded it in and after reviewing the Carfax I did some deeper digging into this vehicle and discovered that there are 3 recalls that have not been serviced. I am hoping that there wasn't any secondary damage due to the recalled items as I haven't noticed anything necessarily wrong with the car but I figured I'd take it in to be safe. I also want a quote for a transmission drain and fill, NOT A FLUSH. The transmission is shifting fine, I just am looking to get it done as preventative maintenance and for peace of mind. The recall repairs are noted in the PDF attached below.

Coolant Intrusion. Started with thick white exhaust when starting up in morning. Turned into acceleration lags, car shutting engine off when parked, and exhaust smell coming inside of car. 2014-2019 models have a recall for cracked engine block allowing cooling to leak inside, but 2020 models do not although there is an increased problem with this year and model of car.

The contact owns a 2020 Ford Fusion. The contact received notification for NHTSA Campaign Number: 23V440000 (Electrical System); however, the part to complete 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.

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.

I was backing out of my drive way when a shift system fault message appeared on my dashboard. When I went to change gears the rotary dial locked up and shifted to park. My safety as well as other people’s safety was put at risk because my car stopped in the middle of the street with little warning. My problem was confirmed by an independent service center with a obd scanner.

While driving at 75mph on the freeway, my 2020 Ford Fusion suffered a sudden, catastrophic EcoBoost engine coolant failure. The vehicle instantly lost power and dropped to 35mph in active traffic, creating an extreme highway collision hazard. A mechanic has confirmed internal coolant intrusion in the engine block.

A failed transmission cooling line caused the transmission fluid to leak. At no point did the vehicle display a check engine light, transmission warning, or any other indication that there was a problem. According to the Ford dealership, the transmission fluid had been leaking for some time. Because the transmission pan is wrapped in a fabric-like insulating material, the leaking fluid was absorbed rather than dripping onto the ground, making the leak virtually impossible for an owner to detect during normal use. The dealership also advised that this condition could have created a potential fire hazard within the engine compartment. The vehicle has only approximately 40,000 miles, making this type of catastrophic transmission failure especially concerning for a relatively low-mileage vehicle. The first and only symptom occurred when I started the vehicle one day. It hesitated, struggled to shift out of first gear, and drove abnormally. I immediately drove it to the Ford dealership, where it was diagnosed with a complete transmission failure. The vehicle is currently at the dealership, and I have been presented with an estimated repair cost of approximately $12,000. My primary concern is that there was absolutely no warning before this major failure. No warning lights, no diagnostic alerts, and no indication that a significant transmission fluid leak or internal transmission damage was occurring. A safety-critical failure of this magnitude should provide drivers with some form of warning before resulting in complete transmission failure.

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.

I’ve learned a while ago that the vehicle doesn’t have a working horn, I’ve replaced the fuse at least five times and it’s still not working. Yes the car was sold to me this way. Also I’ve been getting this warning to my ford app: “The Blind Spot Information System (BLIS)/Cross Traffic Alert (CTA) has detected a fault and may not function. What Should I Do? If either BLIND SPOT NOT AVAILABLE/SENSOR BLOCKED SEE MANUAL or CROSS TRAFFIC NOT AVAILABLE/SENSOR BLOCKED SEE MANUAL is in the information display, the system may not function. Check the exterior vehicle sensors for damage or debris covering them (see Owner's Manual for sensor locations). If the problem persists, please have the system checked by an authorized dealer.” For the last month my car has become hard to drive as if there’s a power steering issue.

I have had this car for 6 years and the transmission has gone out on top of the purge valve, I have seen many people have the same issues with this model and year of this car. THIS NEEDS TO BE ADRESSED. I also see that there is a lawsuit against this issue with the transmission model 6F35

The front left lower control arm (driver's side) snapped off (broke) while turning a corner. There was no reason for the breakage other than turning. It was repaired through insurance. The driver's safety as well as the safety of pedestrians were put at risk because the breakage forced the car to turn sharply to the left. Because of this, the vehicle struck a utility pole. The pole had very little damage, but damage was done to the car. The policeman at the scene inspected the damage, as well as the insurance adjuster in the days following the accident. No warning lights or messages were displayed before the control arm broke. If this had happened at hi-way speeds, it is likely that the resulting loss of control would have resulted in a multi-vehicle accident, resulting in fatalities.

2020 Ford Fusion 1.5L EcoBoost engine completely failed. Ford dealership diagnosed need for complete engine and turbo replacement at $13,475. Believed to be related to known EcoBoost coolant intrusion defect.

Coolant problems and cylinder damage on engine due to coolant intrusion. Ford has not issued a recall on this well known problem and issue on ALL Ford Fusion Models. Several complaints have been made by many Ford Fusion owners for putting drivers and vehicle owners at risk of driving unsafe vehicles and poor driving conditions.

While turning into a parking lot the lower control arm snapped (broke in half, approximately). The picture I sent is of a front lower control arm, however it is not a picture of the actual control arm that broke. After it broke, the car was forced into a sharp left turn, resulting in the car crashing into a telephone pole. The pole was not damaged but there was damage to the car.

The contact owns a 2020 Ford Fusion. The contact stated that upon rolling to a stop, the vehicle started shuddering while depressing the brake pedal. The contact stated that the message "Transmission Not in Park" was displayed. The gear shifter then unexpectedly shifted to several positions independently. The contact discovered a YouTube video that assisted with correcting the issue. The contact used a screwdriver to manually shift the gear shifter back to park(P). The contact was forced to maneuver the shifter back and forth until the gear shifter engaged and resumed normal operation. The contact stated while his wife was driving the vehicle on one occasion, the failure recurred, and the driver was forced to tow the vehicle to a local dealer. Upon investigation, the contact discovered NHTSA Campaign Number: 22V413000 (Power Train) and associated the failure with the recall. The manufacturer was notified of the failure and informed the contact that the vehicle was not included in the recall. The contact was provided a case number. The vehicle was not diagnosed or repaired and remained with the dealer. The failure mileage was approximately 150,000.

I don't know if this qualifies as an immediate safety issue, however, if the vehicle is stopped and placed into park on a busy freeway, or in traffic in any way, then this absolutely is a safety issue after the fact because the vehicle cannot be moved due to not being able to get it into gear. This involves the shift linkage component and not being able to get the car out of park and into any other gear. It's already an active recall but it's VIN specific and my VIN was not included. It really needs to be though. It should be all Fusions at this point. I drive a 2020 Ford Fusion and the shift linkage bushing broke. Initially I got the "shift system error" message back in January and could not get my car into gear. It would just bounce right back into park. I had to call a tow truck but eventually the driver was able to somehow reset the system using the hidden reset button in the center console. It was enough to keep me running for a couple of months. However, two weeks ago it happened again and the reset option was no longer working. The car was towed to my dealership and they replaced the "missing" bushing and I was charged $511.00 for the repairs. Considering how widespread this issue this seems to be, I would like to see a full model-specific recall issued for these Fusions and possibly reimbursement for the costs I was subjected to due to the issue. I can provide the service receipts from the dealership showing that it was replaced and the total cost. Thank you!

Automatic transmission failed No warning No smells no shaking no jerking no light on dash board until it went out that's when it jerk and still no check engine light just a wrench that popped up once

HEAD GASKET FAILING, common problem in car. Broke down in the middle of busy Main Street and started smoking out of exhaust pipes. It has been confirmed by my service center that they now have 3 ford fusions, including mine, that they are replacing a head gasket on right now. They were no warning signs, it happened out of nowhere.

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 (NHTSA 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)

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

Multiple vehicles of the same year make and model had the shifter cable fail within a short amount of time. car would not change gears properly. problem confirmed and fixed by local mechanic shop. no inspections. no warning lights or messages prior to failure.

Shifter Cable broke in multiple vehicles of the same year make and model in our fleet of vehicles within a short amount of time. Car would not change gears properly. Issue confirmed and fixed by a local mechanic shop. No warning messages or other symptoms prior to failure.

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.

I keep getting SHIFT SYS FAULT error. My car will not move out of P (park). I towed my car to repair shop on 2/11/2026 - 02/13/2026 the mechanic told me he replaced the bushing kit and the gear dial. Less than a week later on 02/26/2026 I got the same error and was able to drive my car to Village Ford Dealership (my car is still there) I was told on Monday that the technicians thought they fixed the issue but the same thing happen and now they are unable to get the car out of P (park) and that the technicians would have contact FORD HOTLINE because the repairs are not working. The issue was once recalled on older Ford fusions but according to google 2020 fusions have reported the same issue.

I only have about 45K miles on my car. I began to hear a rattling sound while vehicle is idling and more pronounced with the air conditioning on. I took it to the Ford service department at the dealership where I bought it and was told it was a cracked engine flex plate and it would be a $3000 cost to repair. I was extremely surprised at such an expensive fix for such low mileage and looking online I found a Ford customer satisfaction program 22N12 for this exact issue. I checked and my car was indeed manufactured at the plant in Hermosillo, MX covered in the program. However I was told that I am not covered because it is for the 2.0L engine and not the 1.5L engine. It seems to be more than a coincidence that I would have this issue on this model of car from this manufacturing plant. There were no warning lights of any kind that went off. I have seen that this could have been a major issue had it went unrepaired and caused a major safety issue. I am unfortunately being forced to pay for this out of pocket on such a new car but also this issue is clearly not only on the 2.0L vehicles and the recall/customer satisfaction program should be expanded to include 1.5L

"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)."

COMPONENT: ELECTRICAL SYSTEM, ENGINE I HAVE HAD THIS SENSOR THAT MAKES MY CHECK ENGINE LIGHT STAY ON 3 SEPARATE TIMES! THIS NEEDS TO BE RE CALLED I SEE MULTIPLE COMPLAINTS WITH THE SAME CONCERN

The locking mechanism that keeps the seat belt safely locked into place is malfunctioning. I have to ensure the belt is firmly in place and will not tug out of the lock before going anywhere. The seatbelt will not lock in place properly.

Last month, while transporting my brother to his arm surgery in Chapel Hill, NC, I observed unusual and audible shifting behavior when engaging the vehicle's sport mode. This mode is typically utilized for extended journeys on highways and interstates. Although the anomaly was brief, I did not initially consider it significant. Several weeks later, upon departing from my community college campus, I encountered a red light near Santa Fe Drive. The vehicle exhibited a hesitant and labored acceleration, eventually moving forward. This incident was particularly concerning given the high volume of traffic during that time of day. I subsequently stopped at a nearby 7-Eleven for fuel, suspecting a low fuel level might be the cause. No engine warning lights or mechanical indicators were illuminated, and the oil life was at 70% with appropriate oil levels. Fast forward to the last week of January. On Wednesday the 28th, I began to notice recurring shifting issues with the vehicle during a class break. Additionally, engaging reverse consistently resulted in a harsh shift. As I was leaving my neighborhood to return to class, the vehicle completely failed to engage gears or accelerate. At this point, both the wrench and check engine warning lights illuminated. Upon returning home, I utilized the code reader provided by my mother last Christmas, which displayed the code "P0772." This confirmed my prior research regarding potential issues with the EcoBoost engine. I am relieved that this mechanical failure did not occur amidst the heavy traffic typically found on 210 Murchison South , I-295, Bragg Blvd Fayetteville/Spring Lake and other routes heavily trafficked due to the military base. The high speeds on these roads could have led to a dangerous situation, potentially causing a rear-end accident or other involving other drivers who may be speeding or inattentive. I am grateful that I did not experience a stall in the middle of traffic, which could have compromised my safety.

Back up camera, and touch screen go completely out...the whole system will not come back on until vehicle is shut off and restarted. This has happened multiple times now.

In 2024 on Black Friday while driving home from work my car all of a sudden was starting to lose speed. Even when I'm hitting the gas it would not accelerate and I could push it all the way down to the floor or nothing. And all of a sudden I start to see a whole bunch of monitors go off on my dashboard animal League to the government off and then all of a sudden I started see this underneath my core board pulled over and all sudden those planes coming from my engine and within minutes the whole car was destroyed. Fire department came to drop the fire and everything but the trunk was left essentially. The insurance company has taken to car since and I believed it was sold for parts. I have Thought I had submitted this before but never got somebody you can just in case I messed up. I just feel like a car shouldn't just randomly catch fire

I don't know what failed, but my vehicle spontaneously combusted this morning in front of my apartment.and is a total loss. Fire Marshal's [XXX] ) Case# XX-XXX. The fire also destroyed the vehicle sittling next to it. We are lucky the building didn't catch on fire. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I am the second owner on my Ford fusion 2020 SE all-wheel-drive I got the car at 21,000 I had warranty since I had the warranty. I've been going for this power training code and having them check my car out all the time they always say there's nothing wrong with it. It's just the code is being erased so by the time my warranty went out all these problems are coming up and now they could find those problems I've been inquiring about

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.

When these problems started it was only 6 months after purchase and I was already having issues with power train malfunctions and it didnt want to switch gears. I purchased this at roughly 47,000 miles and it didnt make it to 70,000 miles before I ultimately decided it was not the safe vehicle that was advertised to my family and I. It was taken to the dealership over 3 times in under a year and for some reason the problem never got resolved. I have been sued for the remaining balance now despite that toward the end of my time owning it the vehicle was reving out with barely any pressure on the gas pedal, having issues braking on its own (anti-collision assist), and occasionally the steering wheel would jerk me in to oncoming traffic. I am just trying to get a recall issued at this point because this car is going to kill someone if it stays on the road.

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!

2020 Ford Fusion SE- Transmission problems. Only 98,000 miles on the car and have had issues with this transmission after a year of having it. Transmission fluid was good but there is a small leak, slipping gears, winding, and gear auto shifting back to park. No combustion or power until it hits 60 mph. Has been checked by mechanics. No lights on dash at all!

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