Replaced vehicle battery on 12/30/2013. Check engine light came on before the car was even removed off of the auto center premises. Service center ran vehicle diagnostics check and reported p2112 error indicating an issue with throttle body. Ford dealer ship said the throttle body needs to be replaced which isn't cheap. Faulty electronic throttles are causing these problems. *tr
2009 Ford Fusion electrical problems
severe 17 complaints filed with NHTSA · avg repair $850 · see electrical across all vehicles →
Failure mileage
Complaints
17
Recalls
0
Avg fix
$850
2fires
When does it fail?
Of the 17 electrical complaints filed for the 2009 Ford Fusion, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 15 model years of Ford Fusion we track for electrical problems, this one has the fewest owner complaints on file (17).
No new NHTSA electrical complaint has been filed on this vehicle in over 12 years — the issue may be aging out of the active population.
The failure pattern owners describe
Buyer takeaway: A 2009 Fusion's electrical system is a minefield: throttle bodies fail and strand you in traffic, brake control modules can quit without warning, door locks trap you inside, and multiple owners report fires from electrical faults. Before buying, get a pre-purchase scan and test every electrical function; factor in the cost of potential control module replacements.
The 2009 Fusion's electrical architecture has serious problems. The electronic throttle body is the most common culprit—multiple owners describe sudden loss of acceleration with traction and engine lights, sometimes at highway speeds or in intersections. Dealership technicians have openly told owners Ford knows about this defect. One owner's throttle was replaced but the issue persisted, only to find the computer itself had failed.
Brake system electrical failures rank second. Owners report complete loss of braking with no warning—brake pedals go soft, vehicles won't stop, and the dealer's first move (flushing brake lines) doesn't fix it. One diagnosis pointed to HECU fuse failure; another to ECM failure. A third involved vibration and loss of stopping power at 35 mph.
Door locks and power windows also fail electrically. Owners report being locked inside their cars with doors and windows unresponsive, whether the car is running or off. The driver's side door latch itself breaks on some units.
Fire hazards appear in the narratives too. One owner's charger melted in the accessory outlet under the floor mat and ignited a cabin fire. Another reports electrical fire on wiring near the right front wheel, possibly from cruise control.
Control modules fail wholesale—power control modules, transmission control modules, and smart junction boxes all appear. Battery voltage drops mysteriously. Wiring harnesses burn from oil leaks and become nearly impossible to replace. Chronic brake failures requiring multiple repairs yearly are mentioned.
Same Ford Fusion electrical reports on nearby years: 2006 · 2007 · 2008 · 2010 · 2011
Failure modes owners describe
Electronic Throttle Body Failure
Electronic throttle body becomes unresponsive or fails, preventing normal acceleration. Multiple owners report the dealership identified this as a known Ford issue affecting the 2009 Fusion.
When: Various mileages; one case at 37,000 miles
Symptoms owners cite: Vehicle will not accelerate; Traction light illuminates; Wrench light illuminates; Engine light illuminates; Vehicle shakes; Reduced power; Herky-jerky acceleration
Codes mentioned: P2112
Repairs/costs cited: Dealership replacement of throttle body required; one owner reports it is not cheap.
Recalls/TSBs owners mention: Dealership lady stated Ford has known problems with electronic throttle body failures in 2009 Fusion models.
Secondary Air Injection Pump and Valve Failure
Water intrusion into the secondary air injection pump causes corrosion and failure. When pump fails, the air valve must also be replaced. Owner questions how water enters and what prevents recurrence.
When: Unspecified mileage
Symptoms owners cite: Check engine light; Pump malfunction
Repairs/costs cited: Replacement of both secondary air injection pump and air valve required; owner reports cost of $700 plus.
HECU Fuse Failure
HECU (Hydraulic Electronic Control Unit) fuse fails, causing brake system malfunction. Brake lines were flushed on first visit but problem recurred; second visit identified fuse as the root cause.
When: Approximately 173,890 miles
Symptoms owners cite: Brake pedal depresses with no warning; Loss of braking ability
Repairs/costs cited: HECU fuse replacement needed; dealership did not repair the vehicle.
Recalls/TSBs owners mention: Manufacturer referred contact to NHTSA Hotline.
Electronic Control Module Failure
ECM fails without warning, resulting in loss of braking and inability to stop the vehicle. A Ford mechanic diagnosed the failure but vehicle was not repaired.
When: Approximately 66,000 miles
Symptoms owners cite: Brake pedal becomes very loose; Vehicle vibrates; Vehicle fails to slow down or stop; No warning
Repairs/costs cited: ECM replacement required; vehicle was not repaired.
Accessory Power Outlet Fire Hazard
Charger cable plugged into accessory power outlet becomes hot, melts, and ignites vehicle fire. Cable was located underneath front passenger side floor mat, creating hidden fire risk.
When: Approximately 115,681 miles
Symptoms owners cite: Charger cable overheats; Cable melts; Fire starts on passenger side floor; Hole burned in carpet
Repairs/costs cited: Charger cable melted and burned hole in carpet; fire department extinguished fire.
Throttle Body and Computer Failure (Combined)
Throttle body malfunction triggers warning light and stalling. Dealership replaces throttle body but problem persists. Dealership later determines computer has also failed and requires replacement.
When: Unspecified mileage
Symptoms owners cite: Red warning light flashing intermittently; Vehicle stalls without warning; Unsafe to drive
Repairs/costs cited: Throttle body replacement attempted but failed to resolve issue; computer replacement also required.
Power Control Module and Transmission Control Module Failure
Multiple control modules fail simultaneously, leaving vehicle unable to restart. Battery voltage drops to 9V instead of normal 12V, compounding the electrical failure.
When: Unspecified mileage
Symptoms owners cite: All instrument panel lights illuminate; Vehicle will not restart; Lights, radio, and fan still operational; Low battery voltage
Repairs/costs cited: Main power control module, transmission control module, and battery all required replacement.
Door Lock and Handle Failure
Driver's side door lock and handle both fail. Vehicle cannot be opened from interior; can only be opened from exterior. Lock and unlock functions stop working.
When: Approximately 170,000 miles
Symptoms owners cite: Door locks fail to lock or unlock; Door handle fails; Cannot open vehicle from inside; Can open from outside
Repairs/costs cited: Lock and handle failure; vehicle not repaired.
Intermittent Warning Light Failures
Multiple warning lights on instrument panel illuminate and extinguish intermittently, worsening in humid or rainy conditions. Includes airbag, oil, and engine lights, creating driver uncertainty about vehicle safety.
When: Unspecified mileage
Symptoms owners cite: Warning lights come on and off at will; Worse when humid or raining; Airbag light illuminates intermittently; Oil light illuminates intermittently; Engine light illuminates intermittently
Recalls/TSBs owners mention: Takata recall mentioned but no remedy provided by manufacturer.
Electrical Fire from Cruise Control System
Fire starts on electrical wiring leading to right front wheel, potentially caused by cruise control system malfunction. Owner notes Ford has been having problems with cruise control system.
When: Unspecified mileage; occurred while driving on interstate
Symptoms owners cite: Fire starts on electrical wiring at right front wheel
Repairs/costs cited: Fire department advised dealership inspection; fire extinguished by Minneapolis Fire Department.
Door Latch Failure
Plastic door latch on driver's side breaks, preventing automatic or remote locking of the door. Latch cannot be opened using key fob or other locking features.
When: Unspecified mileage
Symptoms owners cite: Door latch (plastic) breaks; Cannot lock driver's side door automatically; Cannot lock with key fob
Repairs/costs cited: Door latch broken; unable to lock door.
Unintended Acceleration and Power Loss
Vehicle suddenly begins accelerating on its own while in motion on highway, then loses power. No diagnosis or repair information provided.
When: Unspecified mileage; occurred while driving on highway
Symptoms owners cite: Vehicle accelerates on its own; Vehicle loses power
Smart Junction Box Failure
Smart junction box (SJB) fails and requires replacement. Failure occurred early in vehicle life.
When: Approximately 37,000 miles
Symptoms owners cite: Smart junction box failure
Repairs/costs cited: Smart junction box replaced.
Rear Tail Light Socket Corrosion
Rear tail light socket prematurely rusts internally, causing light failure. Socket corrosion prevents proper illumination.
When: Unspecified mileage
Symptoms owners cite: Rear tail lights fail to fully illuminate; Socket prematurely rusted
Repairs/costs cited: Socket corrosion caused internal failure; vehicle not repaired.
Recalls/TSBs owners mention: Manufacturer notified and provided no remedy.
Wiring Harness Damage from Oil Leak
Small oil leak burns through wiring harness, causing acceleration issues. Wiring harness is extremely difficult to locate and replace.
When: Six months after initial sensor diagnosis for acceleration issue
Symptoms owners cite: Herky-jerky acceleration; Burned wiring
Repairs/costs cited: Wiring harness replacement needed but stated as virtually impossible to locate.
Brake System Chronic Failures
Brake system requires repairs and replacements multiple times per year. Chronic brake failures unrelated to specific component.
When: Ongoing; multiple times per year
Symptoms owners cite: Brakes constantly need repairs; Brakes constantly need replacements
Repairs/costs cited: Multiple brake repairs and replacements required throughout year.
Vehicle Lockout Due to Power Door Lock Malfunction
Electrical door lock and window systems malfunction, trapping driver inside vehicle. Occurs with car on or off. Related to Takata airbag recall that has left vehicle worthless and unsafe.
When: Unspecified mileage; happened 2 times
Symptoms owners cite: Door locks malfunction; Window controls malfunction; Driver locked inside vehicle; Occurs with car on or off
Recalls/TSBs owners mention: Takata airbag recall issued; Ford stated no one should sit in front passenger seat.
Synthesized from 17 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Had electrical trouble with your 2009 Ford Fusion?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the electrical problem on the 2009 Ford Fusion?
It's a meaningful issue. 17 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $850.
At what mileage does the electrical typically fail?
Across the 12 complaints that reported odometer mileage, most electrical failures cluster between 59,883 and 120,000 miles, with the median around 80,000. A quarter of owners report trouble before 59,883; a quarter make it past 120,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $850 for electrical repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to electrical?
No active recalls currently cover electrical issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2009/Ford/Fusion.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.