2020 Ford Fusion
Common Problems
Ranked from 62 federal NHTSA complaints and 2 recalls. Every problem links to the complaint IDs behind it.
11 Common Problems
Ordered by how often owners reported each one to NHTSA. The bar shows how common a problem is relative to the most-reported on this vehicle. Expand any problem to see the federal complaint IDs.
- 1
Flex Plate Failure
25complaintsHigh severityTransmissionThe flex plate has cracked, causing severe engine vibrations, knocking sounds, and transmission issues.
- 2
Repeated Battery Issues
17complaintsMedium severityElectricalThe battery repeatedly fails and needs replacement, causing inconvenience and potential safety risks.
Related recalls: 23V440000, 25V685000
- 3
Steering System Failures
6complaintsMedium severitySteeringSteering system malfunctions, causing loss of power steering and difficulty in controlling the vehicle.
- 4
Coolant Intrusion into Engine
5complaintsHigh severityEngineCoolant leaks into the engine causing severe damage and engine failure.
Related recall: 25V685000
- 5
Engine Block Failure
4complaintsHigh severityEngineEngine block failures occur due to coolant intrusion, leading to engine short block replacement.
Related recall: 25V685000
- 6
Engine Knocking and Rattling
4complaintsMedium severityEngineThere is an abnormal knocking and rattling sound coming from the engine, often accompanied by loss of power.
Related recall: 25V685000
- 7
Engine Stall at Idle
3complaintsMedium severityEngineEngine stalls unexpectedly at idle, often without warning, affecting vehicle stability.
$150–$1,200est. stalling / shutdown diagnosis + repair · 1–5 hrs laborGet local quotesRelated recall: 25V685000
- 8
Lower Control Arm Failures
3complaintsHigh severitySuspensionLower control arms break unexpectedly, posing a risk of vehicle loss of control.
$300–$900est. control arm / ball joint replacement · 1.5–4 hrs laborGet local quotes - 9
Shifting Issues and Gear Malfunction
3complaintsMedium severityTransmissionTransmission fails to shift gears correctly, leading to unexpected gear changes and vehicle stalling.
$200–$2,500est. drivetrain diagnosis + repair · 1–8 hrs laborGet local quotes - 10
Battery Pack Issues
2complaintsHigh severityFuel systemHigh-voltage battery pack failures leading to engine shutdown and potential fire hazards.
- 11
Forward Collision Avoidance System Failure
2complaintsSafety riskElectricalThe forward collision avoidance system is failing, particularly in hot weather, leading to potential safety risks.
Related recalls: 23V440000, 25V685000
Other years & sources
Data source: U.S. National Highway Traffic Safety Administration (NHTSA) owner complaints and recalls. Problems are clustered and ranked from the complaint record; occurrence counts reflect corroborating complaints, not total incidence. Vehicle image is illustrative. Repair-cost figures are typical U.S. independent-shop ranges (parts + labor) for the class of repair shown — actual quotes vary by region, engine, and diagnosis; always confirm with a local shop.