2010 Ford Fusion
NHTSA Defect Investigations
The Office of Defects Investigations (ODI) is an office within the NHTSA which investigates serious safety problems in the design, construction or performance of vehicles. The NHTSA is authorized to order manufacturers to recall and repair vehicles, if the ODI finds a safety issue. NHTSA investigations for the 2010 Ford Fusion, both ongoing and closed, are listed below:
Electronic Throttle Body Malfunction NHTSA Preliminary Evaluation #PE13003
Summary: In a letter dated August 30, 2012, The North Carolina Consumers Council (NCCC) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a defect investigation of alleged electronic throttle body failures resulting in engine stall or surge while driving in model year (MY) 2005 through 2012 Ford Escape vehicles.On October 2, 2012 the Office of Defects Investigation (ODI) opened a Defect Petition DP12-006 to evaluate whether to grant or deny the petition. The petition is hereby granted on certain model years.The NCCC letter cites two complaints of stall while driving in MY 2009 Ford Escape vehicles that were diagnosed as failed throttle bodies with diagnostic trouble codes (DTC) P2111, Throttle Body Stuck Open, and P2112, Throttle Body Stuck Closed. The petitioner indicates that the owners of both vehicles reported experiencing repeated incidents of stalling and engine surging.According to Ford, Escape non-hybrid vehicles are equipped with Electronic Throttle Body (ETB) assemblies beginning with MY 2009.Vehicles manufactured between June 22, 2009 and October 15, 2009 may contain contaminated printed circuit boards (PCB) with plating variations. Plating variations could lead to a lack of continuity in the throttle position sensor circuit where P2111 and/or other DTCs would be generated and stored.Ford and its electronic throttle body supplier, Delphi, modified the PCB manufacturing process and issued a technical service bulletin (TSB) 09-23-5.Vehicles produced after October 15, 2009 incorporated ETBs manufactured with a PCB process that resolved this condition.ODI's analysis identified a total of 123 unique reports indicating allegations of reduced motive power or vehicle stall.Depending on the condition of throttle control system malfunction, a driver may experience varying levels of reduced engine performance associated with three limp home modes.In two limp modes, reduced engine performance may maintain vehicle speeds above 20mph while the third is a limited limp home mode with engine speeds limited to approximately 900 RPM. Allegations of stall appear to be related to the limited limp home mode.Vehicles are not likely to unexpectedly stall as a result of this condition, but drivers may characterize the reduced functionality as a stall, even though their vehicle may still has motive capability.Allegations of vehicle surge appear to be related to limp home mode operation.Complaints alleging surge are most likely related to engine RPM fluctuations at low vehicle speeds or idle as the control system engages to prevent engine stall.In limited limp mode, rough-idle conditions may exist while the control system attempts to modulate engine RPMs once the vehicle reaches a reduced speed to maintain approximately 900 RPM.Separately, ODI received 59 complaints alleging incidents of engine stall while driving in model year (MY) 2010-2011 Ford Fusion vehicles.Approximately 60 percent (36) of the incidents occurred at speeds of 40 miles per hour or more.Eighty percent of complaints (47) were received beginning March 2012 and 14 complaints reported that the throttle body was replaced or DTCs associated with limp home modes. Additionally, Ford issued TSB 10-21-6 addressing DTCs associated with idle speed drops and limited limp home mode.The complaints show an apparent increasing trend.A Preliminary Evaluation has been opened to assess the scope, frequency and potential safety consequences associated with the alleged defect.See additional information for the VOQs associated with the opening of this investigation.
NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE13003 »
Fleet Vehicle Recall Completion Audit NHTSA Defect Investigation #AQ10001
Component(s): Unknown Or Other
Summary: The agency, particularly in recent months, has been informed of incidents involving allegations of personal injury and death claimed to have been caused by safety defects and failures to conform to minimum Federal Motor Vehicle Safety Standards (FMVSS) on rental car vehicles for which a safety recall to remedy the safety defect or noncompliance had allegedly not been performed prior to the rental car company's lease of the vehicle.NHTSA understands that there is presently a petition before the Federal Trade Commission (FTC) seeking to prohibit at least one rental car company from renting vehicles on which safety recall campaign remedies remain outstanding.The purpose of this audit query (AQ) is to investigate recall remedy completion by rental car companies on the above-listed safety recall campaigns.These campaigns were chosen due to their inclusion of vehicles used in the rental market.This information is expected to provide the agency an indication of how completely and how quickly rental car fleets, in general or individually, perform necessary recall-related repairs or other remedies on the vehicles owned and then leased for use on the roadways.This AQ is opened.
NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #AQ10001 »
Accelerator Pedal Interference NHTSA Engineering Analysis #EA12009
Component(s): Vehicle Speed Control
Vehicle Speed Control:Accelerator Pedal
Summary: 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.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
NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA12009 »
Accel Pedal Interference - Acc Floormat NHTSA Preliminary Evaluation #PE10019
Component(s): Vehicle Speed Control:Accelerator Pedal
Summary: 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
NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE10019 »
Wheel Mounting Stud Fracture NHTSA Engineering Analysis #EA11009
Summary: 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/owners/SearchNHTSAID 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.
NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA11009 »
Wheel Stud Fracture NHTSA Preliminary Evaluation #PE11003
Summary: 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.
NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE11003 »