Owners of 2011 Ford Fusions report three critical fuel-system issues. The most common is throttle body failure: the engine suddenly stops responding to the accelerator pedal at any speed, from city streets to interstates, sometimes without warning and sometimes preceded by rough running or a wrench light. The vehicle either slows drastically or stalls, forcing drivers to coast to safety. After turning off and restarting, it typically runs normally again—at least temporarily. Some owners experience this repeatedly over weeks; others see it come and go. Dealerships acknowledge this is a known problem and have seen it on hundreds of other Fusions. Ford has redesigned the throttle body but refuses to issue a recall. The replacement cost runs $400–$640, and parts availability has been problematic due to high demand.
Fuel tank leaks represent the second major issue. Owners report strong gasoline odors and visible fuel dripping during or after driving, starting at 39,000 miles and continuing into the 230,000-mile range. A known recall campaign (15V793000) exists, but Ford denies coverage to many owners whose vehicles fall within the recall date window, citing VIN exclusions. Dealerships charge additional diagnostic fees and offer no guarantee of repair.
Finally, several owners report unintended acceleration or surging, particularly when braking or at low speeds, sometimes resulting in minor collisions. One owner reported this occurring even after the throttle positioner had already been replaced. Purge valve canister failures also appear in complaints, with the valve failing repeatedly even after replacement.
Failure modes owners describe
Throttle body failure—sudden loss of power
Engine loses response to accelerator pedal without warning; vehicle decelerates or stalls. Gas pedal becomes unresponsive while driving. Owners report no acceleration even when depressing pedal fully.
When: Occurs at various speeds from 5 mph to 70 mph; some owners report recurring episodes over weeks or months, others experience it intermittently after first failure
Symptoms owners cite: No throttle response when depressing gas pedal; Engine stalls or enters limp mode; Vehicle slows dramatically or comes to a stop; Engine shaking or rough running before stall; Wrench warning light illuminates; Check engine light may illuminate; Vehicle may recover after turning off and restarting
Codes mentioned: P2111, P2112
Repairs/costs cited: Throttle body replacement. Owners report $400–$640 repair costs. Some owners cite 2-week parts availability delays due to high volume of failures. Ford has redesigned the part but has not issued a recall.
Recalls/TSBs owners mention: Dealers acknowledge this is a known issue. Service technicians report seeing 100+ cases on other Fusions. Ford has updated throttle body design but refuses to issue recall. Dealership technicians state they cannot repair without diagnostic codes present; codes often clear within driving cycles.
Fuel leak from tank
Cracked or faulty fuel tank leaks gasoline onto ground or inside vehicle. Abnormal fuel odor present during and after driving. NHTSA recall 15V793000 exists for fuel system issues; however, many owners report their vehicles were manufactured within recall date range but excluded from campaign.
When: Detected at various mileages: 39,000 to 234,000 miles. Some owners notice smell after refueling or parking vehicle after driving.
Symptoms owners cite: Strong abnormal gasoline odor in vehicle; Visible fuel dripping from vehicle or leaking to ground; Smell detected at top 1/8 of fuel tank; Fuel leaks while refueling; No warning light typically present
Repairs/costs cited: Fuel tank replacement required. Owners report this is expensive. One owner cited medical treatment for injuries sustained; another unable to afford repair and concerned about child safety.
Recalls/TSBs owners mention: NHTSA Campaign 15V793000 (Fuel System, Gasoline) exists for 2010–2011 Fusions. Owners report Ford states their VIN does not qualify even though vehicle manufacture date falls within recall window. Dealer diagnostic testing costs additional fees. Ford has referred owners to NHTSA rather than assisting under recall.
Unintended acceleration or surging
Vehicle accelerates without driver input or surges forward unexpectedly, especially when coming to a stop or at low speeds. Throttle positioner or electronic throttle control malfunctions.
When: Occurs when braking, at stop signs, or at low speeds (under 20 mph); also reported during highway driving
Symptoms owners cite: Sudden acceleration without pedal depression; Vehicle lurches or surges forward; Occurs when applying brakes; No warning lights in some cases; Check engine light may illuminate
Repairs/costs cited: Throttle positioner replacement reported by one owner; cost not stated. One owner reported this occurred after throttle positioner had previously been replaced by dealer.
Recalls/TSBs owners mention: One owner reports throttle positioner was replaced months before unintended acceleration occurred, suggesting repair may not resolve underlying issue.
Purge valve canister failure
Emissions system canister purge valve malfunctions, causing check engine light and hesitation during acceleration. Valve fails shortly after replacement or fails repeatedly.
When: Mileage range 90,000–131,000 miles noted in complaints
Symptoms owners cite: Check engine light illuminates; Vehicle hesitation during acceleration; Fuel odor; Abnormal fuel fill inlet message displayed
Codes mentioned: EVAP system error
Repairs/costs cited: Purge valve replacement. One owner replaced valve himself but it failed again within 24 hours.
Recalls/TSBs owners mention: Owners cite Technical Service Bulletin 15S34, but dealers state TSB does not apply to their vehicle. Related to NHTSA Campaign 15V793000 but some vehicles not included despite recall notification.
Fuel filler inlet malfunction
Fuel filler or fuel fill inlet fails, preventing proper refueling and causing vehicle stalling.
When: One report at 64,000 miles; another at undisclosed mileage
Symptoms owners cite: Vehicle stalls without warning; Check engine light illuminates; Message display 'Check Fuel Fill Inlet' appears; Difficulty or inability to refuel
Repairs/costs cited: Fuel filler replacement reported at $390 cost.
Synthesized from 57 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.