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2010 FORD FUSION Defect Investigation Open 2011/07/26 - Close 2012/01/20 NHTSA #: EA11009
NHTSA Recall #: 11V574000
WHEELS:LUGS/NUTS/BOLTS: To date, the agency is aware of 84 consumer complaints and 361 warranty claims related to the alleged defect in the subject vehicles.In total, 382 subject vehicles reportedly experienced one or more wheel stud fractures, resulting in 7 alleged wheel separation incidents.Most of the reported wheel stud fractures occurred on subject vehicles originally equipped with 17 inch diameter steel wheels (368 of 382) as did all 7 alleged wheel separation incidents.Of the 7 alleged wheel separation incidents, 5 reportedly involved a wheel becoming detached from the subject vehicle's rear axle.The subject vehicles are designed with a safety margin that requires validation of proper wheel joint function with one missing lug nut and all other lug nuts at the minimum torque specification.If multiple stud fractures occur at a wheel location, analysis of reports indicates that the operator may observe vehicle vibration. If the vibration is ignored and the vehicle continues to be driven the remaining studs may fracture, resulting in a wheel separation.By letter dated December 5, 2011, the manufacturer notified the agency that it will conduct a safety recall (identified by NHTSA Recall No.11V-574 and Ford Recall No. 11S23) on certain 2010 and 2011 model year Ford Fusion and Mercury Milan vehicles to address the potential for wheel separation.The recall vehicles were originally equipped with 17 inch diameter steel wheels and were built from April 1, 2009, through April 30, 2009, and from December 1, 2009, through November 13, 2010.Approximately 128,616 vehicles are potentially affected as well as approximately 2,940 service steel wheels distributed to authorized Ford dealers.Ford has identified two distinct root causes of wheel stud fracture in the recall vehicles.First, certain steel wheel centers may have been stamped improperly such that the mounting pad lacks the necessary concavity, which reduces the diameter of the outermost radial points of contact with the brake rotor.This reduces the Belleville washer effect, which reduces the clamp load of the joint.Second, the wheel mounting face on certain rear brake discs may have been machined improperly due to a damaged dust boot on a gauge that measures rear brake rotor parallelism (flatness), resulting in a wheel mounting face that is convex.One or both conditions may induce bending fatigue in the wheel studs.Ford's analysis of manufacturing process information showed that one or both of these two conditions may have been out of control during parts of one or both production ranges covered by the recall.Owners will be notified by mail and instructed to take their vehicles to an authorized Ford or Lincoln dealer to have the lug nuts replaced on all four wheels with new lug nuts treated with a proprietary low-friction coating that improves clamp load given the same applied torque value, and to have the rear brake discs inspected for wheel mounting surface flatness and replaced, if required.Ford will instruct dealers to notify customers who purchased service steel wheels, where information is available, to return vehicles for lug nut replacement.Accordingly, this investigation is closed.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/complaints under the following identification (ODI) numbers: 10364337, 10373257, 10378953, 10381431, 10389641, 10389940, 10392373, 10395676, 10396577, 10400071, 10402309, 10416653, 10419175, 10419734, 10420116, 10424191, 10432393, 10434188, 10436471, 10438725 and 10440830.
2010 FORD FUSION Defect Investigation Open 2011/01/21 - Close 2011/07/26 NHTSA #: PE11003
NHTSA Recall #: 11V574000
WHEELS:LUGS/NUTS/BOLTS: On January 21, 2011, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE11-003) to investigate alleged wheel stud fractures in certain model year (MY) 2010 Ford Fusion vehicles.ODI sent the manufacturer an information request letter dated February 8, 2011 and Ford responded by letter dated March 25, 2011.Ford provided a supplemental response by letter dated July 15, 2011.To date, ODI is aware of 29 complaints related to the alleged defect in the subject vehicles, which now include certain MY2010 Mercury Milan vehicles that are the same or substantially similar to the subject Ford Fusion vehicles in regards to the alleged defect.In total, ODI is aware of 4 reported wheel separation incidents related to the alleged defect in the subject vehicles.The manufacturer's investigation into the root cause of the alleged defect is ongoing.Accordingly, this investigation has been upgraded to an Engineering Analysis (EA11-009) to further study the alleged defect.
2010 FORD FUSION Defect Investigation Open 2010/05/28 - Close 2013/01/11 NHTSA #: PE10019
VEHICLE SPEED CONTROL:ACCELERATOR PEDAL: Unsecured mats may interfere with accelerator pedal return to idle. A heel blocker in the floor pan provides a platform that may lift an unsecured mat into contact with the pedal. Ford introduced new pedals as a running change early in model year (MY) 2010 vehicles. Analysis of complaints received by ODI and Ford show elevated rates of pedal entrapment incidents in MY 2008 through early 2010 production vehicles. Incidents typically occur following hard pedal applications to pass slower traffic or when merging into faster traffic. Drivers allege continued high engine power after releasing the accelerator pedal and difficulty braking, including reports that the incident was controlled by shifting to neutral or turning the engine off. Drivers and service technicians reference observing evidence of mat interference or note unsecured Ford or aftermarket all weather floor mats in post-incident inspections.Based on information gathered during the Preliminary Evaluation the population being investigated has been narrowed to model years 2008 to 2010.This investigation has been upgraded to an engineering analysis on MY 2008 through early-2010 vehicles (produced through September 2009) to further assess the scope, frequency and safety consequences of the alleged defect.The VOQs associated with the opening of this Engineering Analysis are: 10479693, 10415911, 10379562, 10372674, 10345830, 10342572, 10339330, 10335336, 10334211, 10332233, 10331160, 10329659, 10327597, 10320011, 10232027, 10214131
2010 FORD FUSION Technical Service Bulletin 2013/04/01 NHTSA #: 10052191
Service Bulletin #: SB-32167-70
(PWS): FORD/LINCOLN/MERCURY: SOME VEHICLES MAY EXPERIENCE AN ILLUMINATED MIL OR SAFETY STOP NOW MESSAGE, OR A NO START CONDITION OR POSSIBLE MISFIRE OR ROUGHNESS AT IDLING THROUGH 2000RPM OR A LACK OF ACCELERATION. MODELS 2009-12 ESCAPE, 2009-1
2010 FORD FUSION Technical Service Bulletin 2012/05/30 NHTSA #: 10044899
Service Bulletin #: TSB-12-5-14
ELECTRICAL SYSTEM: FORD/LINCOLN: A DIAGNOSTIC TROUBLE CODE (DTC) P0A0A (HIGH VOLTAGE SYSTEM INTERLOCK CIRCUIT) SHOWS WHEN CERTAIN VEHICLES EXPERIENCE RED TRIANGLE ON/STOP SAFELY NOW MESSAGE AND/OR A CONDITION OF NO START. *PE
2010 FORD FUSION Technical Service Bulletin 2012/05/30 NHTSA #: 10044899
Service Bulletin #: TSB-12-5-14
(PWS): FORD/LINCOLN: A DIAGNOSTIC TROUBLE CODE (DTC) P0A0A (HIGH VOLTAGE SYSTEM INTERLOCK CIRCUIT) SHOWS WHEN CERTAIN VEHICLES EXPERIENCE RED TRIANGLE ON/STOP SAFELY NOW MESSAGE AND/OR A CONDITION OF NO START. *PE
2010 FORD FUSION Technical Service Bulletin 2012/02/28 NHTSA #: 10032445
Service Bulletin #: CSP-10B13
ELECTRICAL SYSTEM: SOFTWARE: FORD\MERCURY SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. ON SOME AFFECTED VEHICLES, THE BRAKE SYSTEM SOFTWARE MAY UNNECESSARILY CAUSE THE REGENERATIVE BRAKE SYSTEM TO TRANSITION TO CONVENTIONAL BRAKES WITH FULL ANTILOCK
2010 FORD FUSION Technical Service Bulletin 2012/02/28 NHTSA #: 10032445
Service Bulletin #: CSP-10B13
POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM, PCM): FORD\MERCURY SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. ON SOME AFFECTED VEHICLES, THE BRAKE SYSTEM SOFTWARE MAY UNNECESSARILY CAUSE THE REGENERATIVE BRAKE SYSTEM TO TRANSITION TO CONVENTIONAL BRAKES WITH FULL ANTILOCK
2010 FORD FUSION Technical Service Bulletin 2012/02/28 NHTSA #: 10032445
Service Bulletin #: CSP-10B13
SERVICE BRAKES, AIR:ANTILOCK:ABS WARNING LIGHT: FORD\MERCURY SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. ON SOME AFFECTED VEHICLES, THE BRAKE SYSTEM SOFTWARE MAY UNNECESSARILY CAUSE THE REGENERATIVE BRAKE SYSTEM TO TRANSITION TO CONVENTIONAL BRAKES WITH FULL ANTILOCK
2010 FORD FUSION Technical Service Bulletin 2012/02/28 NHTSA #: 10032445
Service Bulletin #: CSP-10B13
SERVICE BRAKES, HYDRAULIC:ANTILOCK:ABS WARNING LIGHT: FORD\MERCURY SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. ON SOME AFFECTED VEHICLES, THE BRAKE SYSTEM SOFTWARE MAY UNNECESSARILY CAUSE THE REGENERATIVE BRAKE SYSTEM TO TRANSITION TO CONVENTIONAL BRAKES WITH FULL ANTILOCK
2010 FORD FUSION Technical Service Bulletin 2012/01/26 NHTSA #: 10043325
Service Bulletin #: TSB-12-1-18
DIGITAL INSTRUMENT PANEL: FORD/MERCURY/LINCOLN: SOME MODEL YEAR VEHICLES MAY EXHIBIT A MESSAGE WITH A RED TRIANGLE ON AND STOP SAFELY NOW, AND/OR HAVE A DIAGNOSTIC TROUBLE CODE, NO START CONDITION. *PE
2010 FORD FUSION Technical Service Bulletin 2012/01/26 NHTSA #: 10043325
Service Bulletin #: TSB-12-1-18
ENGINE AND ENGINE COOLING:ENGINE: FORD/MERCURY/LINCOLN: SOME MODEL YEAR VEHICLES MAY EXHIBIT A MESSAGE WITH A RED TRIANGLE ON AND STOP SAFELY NOW, AND/OR HAVE A DIAGNOSTIC TROUBLE CODE, NO START CONDITION. *PE
2010 FORD FUSION Technical Service Bulletin 2012/01/01 NHTSA #: 10043648
Service Bulletin #: ASI-22173
ENGINE AND ENGINE COOLING:ENGINE: FORD: THE VARIABLE CAMSHAFT TIMING VCT) SOLENOID MOVEMENT MAY BE TEMPORARILY RESTRICTED DUE TO DEBRIS IN ENGINE OIL THAT IS CAUSING DIAGNOSTIC TROUBLE CODES (DTCS). *PE
2010 FORD FUSION Technical Service Bulletin 2011/11/09 NHTSA #: 10042506
Service Bulletin #: TSB-11-11-10
EXTERIOR LIGHTING:BRAKE LIGHTS: MERCURY/LINCOLN/FORD: THE RED BRAKE LAMP WILL ILLUMINATE WITH NO CHANGE IN BRAKE PEDAL FEEL. *PE
2010 FORD FUSION Technical Service Bulletin 2011/08/16 NHTSA #: 10041932
Service Bulletin #: TSB-11-8-8
ENGINE AND ENGINE COOLING:ENGINE: FORD: AFTER REFUELING VEHICLE, WOULD BE HARD TO START, RUNS ROUGH AND AN AUDIBLE CLICKING NOISE CAN BE HEARD. *PE
2010 FORD FUSION Technical Service Bulletin 2011/05/04 NHTSA #: 10039081
Service Bulletin #: TSB-11-5-2
ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR: FORD: ENGINE POWER MAY BE REDUCED WITH A HIGH IDLE SPEED. THE ENGINE LIGHT MAY ALSO BE ON WITH A STORED TROUBLE CODE. PROGRAMMING ISSUE. 2010-2011 FUSION/MERUCRY MILAN/LINCOLN MKZ. *RM
2010 FORD FUSION Technical Service Bulletin 2011/05/04 NHTSA #: 10039081
Service Bulletin #: TSB-11-5-2
ELECTRICAL SYSTEM: SOFTWARE: FORD: ENGINE POWER MAY BE REDUCED WITH A HIGH IDLE SPEED. THE ENGINE LIGHT MAY ALSO BE ON WITH A STORED TROUBLE CODE. PROGRAMMING ISSUE. 2010-2011 FUSION/MERUCRY MILAN/LINCOLN MKZ. *RM
2010 FORD FUSION Technical Service Bulletin 2011/05/04 NHTSA #: 10039081
Service Bulletin #: TSB-11-5-2
POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM, PCM): FORD: ENGINE POWER MAY BE REDUCED WITH A HIGH IDLE SPEED. THE ENGINE LIGHT MAY ALSO BE ON WITH A STORED TROUBLE CODE. PROGRAMMING ISSUE. 2010-2011 FUSION/MERUCRY MILAN/LINCOLN MKZ. *RM
2010 FORD FUSION Technical Service Bulletin 2011/05/02 NHTSA #: 10038904
Service Bulletin #: TSB-11-4-23
VISIBILITY:WINDSHIELD WIPER/WASHER: FORD: 2010-2011 FUSION. SERVICE ENGINE SOON LIGHT IS ON WITH THREE POSSIBLE TROUBLE CODES STORED DURING WINDSHIELD WIPER USE. *RM
2010 FORD FUSION Technical Service Bulletin 2011/04/01 NHTSA #: 10038965
Service Bulletin #: SIS-21841
AIR BAGS: COMM-TRANS LUND: SOME 2009-2011 MODELS MAY HAVE THE AIR BAG INICATOR FLASHING WITH A STORED TROUBLE CODE. THIS IS A SOFTWARE PROBLEM. *RM
 
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