Some Ford and Lincoln vehicles may exhibit noise when the brakes are applied. When diagnosing and repairing brake noise conditions, use the Workshop Manual (WSM) and the appropriate pinpoint test in section 206-00. The brake rotors should only be machined if directed by the WSM because one or more of the following conditions are present on the braking surface: scoring, excessive corrosion/rust or pitting, bluing/discoloration and/or heat spots. For additional information, refer to WSM section 206-00.
full bulletin at NHTSA ↗2016 Ford Fusion brakes problems
severe Owners of the 2016 Ford Fusion have filed 97 NHTSA complaints about the brakes, typically surfacing around 93,530 miles at roughly $450 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See brakes across all vehicles →
Failure mileage
Complaints
97
Recalls
0
Avg fix
$450
| Model year | brakes complaints |
|---|---|
| 2012 Fusion | 89 |
| 2013 Fusion | 52 |
| 2014 Fusion | 91 |
| 2015 Fusion | 109 |
| 2016 Fusion (this page) | 97 |
| 2017 Fusion | 83 |
| 2018 Fusion | 4 |
| 2020 Fusion | 5 |
7crashes
1fire
4injuries
When does it fail?
Of the 97 brakes complaints filed for the 2016 Ford Fusion, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 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
Owners have filed 97 brakes complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
No new NHTSA brakes complaint has been filed on this vehicle in over 7 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering brakes on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Some 2013-2016 Escape/Fusion/MKZ vehicles may display an error message when updating the All Wheel Drive-ATC Barcode using the IDS service function after installing a new rear drive unit assembly (RDU) or active torque coupling (ATC) clutch assembly. To prevent this error from occurring, enter the universal ATC 4 digit barcode 7772. Once programmed, perform several figure 8 turns at parking lot speeds to verify there is no binding from the all wheel drive (AWD) system. If the vehicle binds in a turn, perform Pinpoint Test A. Refer to the Workshop Manual (WSM), Section 308-07A > Diagnosis and Testing.
full bulletin at NHTSA ↗Some Ford and Lincoln vehicles may exhibit noise when the brakes are applied. When diagnosing and repairing brake noise conditions, use the Workshop Manual (WSM) and the appropriate pinpoint test in section 206-00. The brake rotors should only be machined if directed by the WSM because one or more of the following conditions are present on the braking surface: scoring, excessive corrosion/rust or pitting, bluing/discoloration and/or heat spots. For additional information, refer to WSM section 206-00.
full bulletin at NHTSA ↗Certain 2015-2019 Model Year Edge and Lincoln MKX Vehicles and 2013-2018 Model Year Fusion and Lincoln MKZ Vehicles Front Brake Flexible Hose Replacement REASON FOR THIS SUPPLEMENT Parts Requirements / Ordering Information: Part numbers for Edge and MKX vehicles have been added. Edge and MKX model year updated from 2018 to 2019, build dates remain the same.
full bulletin at NHTSA ↗Certain 2015-2018 Model Year Edge and Lincoln MKX Vehicles and 2013-2018 Model Year Fusion and Lincoln MKZ Vehicles Front Brake Flexible Hose Replacement Submitting Owner Letters
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2016 Fusion brake system shows persistent failure patterns affecting hydraulics, switches, and housings. Most critical are sudden brake failures where the pedal sinks to the floor with minimal stopping power—reported at speeds from 5 to 75 mph, with owners describing near-misses and actual collisions involving pedestrians and other vehicles. Brake hoses rupture or develop slow leaks that drain fluid completely, and multiple owners report that dealership "inspections" failed to catch obvious issues.
Plastic components are a recurring problem. The brake pedal switch holder and button, made of plastic in an area with engine heat underneath the dash, become brittle and disintegrate. When they fail, brake lights either stay on all the time or stop working entirely. Owners report replacing the entire pedal assembly at $585–$700. One owner found even used replacement parts had the same brittle plastic failure.
Ford issued recall 23V162000 for hydraulic brake failures, but many owners waited over a year with "parts not available" notifications while driving unsafe vehicles. Some dealerships completed brake work but warning lights (ABS, StabiliTrak) stayed on afterward. A parking brake malfunction light in one vehicle came back after 18 separate dealer visits over six years. One owner documented the brake booster (vacuum pump) suddenly failing, turning the pedal rock-hard mid-drive, and a rear brake caliper failed twice in one vehicle within 1,500 miles of driving.
Same Ford Fusion brakes reports on nearby years: 2013 · 2014 · 2015 · 2017
Failure modes owners describe
Brake Pedal Switch Assembly Degradation (Plastic Holder/Button)
The plastic brake pedal switch holder and button deteriorate and disintegrate due to heat exposure from the engine, causing loss of brake light function and intermittent brake light activation. The entire pedal assembly must be replaced at substantial cost, and the dash must be removed for replacement.
When: Various mileages; occurs with normal wear over time
Symptoms owners cite: Brake lights stay on continuously; Loss of brake light function; Brake lights come on spontaneously; Unable to accelerate or vehicle decelerates unexpectedly; Plastic pieces falling apart under the pedal
Repairs/costs cited: Complete brake pedal assembly replacement required; cost approximately $585 to $700+ including labor. Plastic components fail repeatedly even on used parts sourced as replacements.
Recalls/TSBs owners mention: Previous model years (2013-2015) recalled for same issue but 2016 design not changed. Ford was aware of the defect but did not issue recall for 2016 model.
Parking Brake Malfunction Warning Light (Recurring)
Parking brake malfunction warning light activates repeatedly and cannot be permanently resolved by dealer repairs. Additional brake system warning lights appear when the primary light illuminates. Owners report 18+ service visits with no permanent fix.
When: Started May 2017; recurring monthly through 2023
Symptoms owners cite: Park brake malfunction light comes on; Additional brake system warning lights appear with main light; Light returns repeatedly after service visits
Repairs/costs cited: Multiple dealer repair attempts over 6+ years (18 documented service visits) with no resolution
Recalls/TSBs owners mention: No recall issued; dealership unable to resolve despite repeated service
Complete Brake Failure - Pedal to Floor
Brake pedal loses all or nearly all stopping power and sinks to the floorboard with little to no resistance, resulting in inability to slow or stop the vehicle. Occurs at highway and city speeds with no warning. Multiple reported incidents resulting in collisions.
When: Reported at various mileages: 40k, 70k, 71.5k, 89k, 90k, 91k, 102k, 103k, 110k, 135k, 146k, 150k, 174k, 179k miles
Symptoms owners cite: Brake pedal goes to floorboard with no resistance; Minimal or zero stopping power; Low brake fluid warning light illuminates; Check brake warning light illuminates; Brake fluid leaks visible under vehicle; Vehicle continues forward after pedal depressed; Smoke from engine compartment in one case
Repairs/costs cited: Brake hose replacement (front and rear) required; costs reported between $400-$600 for parts, labor, and towing. One owner reported $172.98 tow fee plus additional towing costs.
Recalls/TSBs owners mention: NHTSA Campaign 23V162000 issued for hydraulic brake failure but parts unavailable for extended periods. Customers advised parts not yet available despite recall notifications.
Front Brake Hose Rupture/Leak
Front brake hoses split, rupture, or bulge, causing brake fluid to leak. Fluid loss renders brakes inoperable or severely degraded. Hoses fail suddenly with no prior warning in most cases.
When: Various mileages from 29k to 174k miles; failures occur suddenly
Symptoms owners cite: Brake pedal soft or goes to floor; Brake fluid puddles on driveway or visible under wheels; Low brake fluid warning light; Oily spots on inner wheel rims; Brake fluid leaking from front driver or passenger side; Bulging hose (visual inspection)
Repairs/costs cited: Both front brake hoses replaced; costs over $400 in parts, labor, and towing reported. One case cited over $600 for right rear caliper, hoses, and pads.
Recalls/TSBs owners mention: Ford issued 'Customer Satisfaction Program' for one-time front brake hose replacement; NHTSA Campaign 23V162000 for hydraulic brakes issued but parts not available for months to over 1 year after recall notification.
Rear Brake Hose/Line Failure
Rear brake hoses rupture or develop severe leaks, causing brake fluid loss and brake failure. Similar to front hose failures.
When: Reported at approximately 62k and 110k miles
Symptoms owners cite: Brake pedal goes to floor; Brake fluid loss/leak from rear wheel well; Low brake fluid warning; Brakes fail to respond
Repairs/costs cited: Rear brake hoses replaced; repair costs not specified in narratives
Recalls/TSBs owners mention: Recall 23V162000 may cover but parts availability variable
Brake Booster Failure
Brake booster (vacuum pump) fails, causing brake pedal to become extremely stiff and hard to press. Brakes stop working or become inoperable. Pedal requires extreme force to produce any braking effect.
When: Occurs at various speeds with no prior warning
Symptoms owners cite: Brake pedal becomes extremely stiff and hard to press; Brakes stop working suddenly; No warning lights prior to failure; Pedal requires excessive force to slow vehicle
Repairs/costs cited: Dealership diagnostic indicated need to replace engine camshaft, vacuum pump, and related gaskets/hardware; vehicle not drivable until repair completed
Recalls/TSBs owners mention: Dealership diagnosed vacuum pump (brake booster) issue; note that F-150 trucks have same component under recall
ABS/Stability Control Warning Lights (Post-Recall)
After recall repair completion, ABS warning light and StabiliTrak light remain illuminated or reappear. ABS sensor failure diagnosed but not resolved.
When: Occurred after recall repair at 172k miles
Symptoms owners cite: ABS warning light illuminated; StabiliTrak warning light illuminated; Lights do not turn off after recall repair; Require added brake pedal pressure to stop vehicle
Repairs/costs cited: ABS sensor replacement needed but not performed; issue unresolved
Recalls/TSBs owners mention: Dealership technician said recall completion should eliminate warning lights; did not occur
Brake Line Damage/Corrosion
Front brake lines severely damaged or corroded. One case involved brake line rupture from apparent rodent wire damage, though owner disputes rodent cause.
When: Not specified in all cases; one case had damaged lines discovered during recall work
Symptoms owners cite: Complete brake failure; Can only stop using park gear; Brake fluid loss
Repairs/costs cited: One owner charged $420 for repair after dealership attributed failure to rodent damage; brake lines and hoses require replacement in multiple cases
Recalls/TSBs owners mention: No response documented; owner disputes rodent diagnosis
Intermittent Brake Pedal Issues - Soft Pedal/Delayed Response
Brake pedal feels softer than normal, depresses closer to floorboard than normal, or brakes respond intermittently with delayed stopping. Issues occur inconsistently.
When: Reported at various mileages; intermittent nature makes prediction difficult
Symptoms owners cite: Brake pedal depresses closer to floor than normal; Brakes fail to stop vehicle immediately; Soft brake pedal feel; Intermittent brake response; Brake pedal pushed back while depressing
Repairs/costs cited: Dealer testing unable to verify concern in some cases; owner reported needing to constantly add brake fluid
Recalls/TSBs owners mention: Recall 23V162000 issued; dealers claim unable to replicate issue in some cases
Caliper Failure
Brake calipers fail suddenly, typically in rear, causing loss of braking power in that wheel circuit.
When: Reported at 70k and 71.5k miles in same vehicle; two failures within 1,500 miles
Symptoms owners cite: Brake pedal goes to floor; Sudden loss of braking power; No warning prior to failure
Repairs/costs cited: Right rear caliper replacement at 70k miles cost approximately $600 (including hoses and ceramic pads); left side caliper failure at 71.5k miles
Recalls/TSBs owners mention: No recall issued; owner plans to dispose of vehicle
Brake Fluid Leakage from Multiple Sources
Brake fluid leaks from front or rear brake hoses, lines, or calipers, causing system pressure loss and brake failure.
When: Reported at various mileages; some leak out completely within minutes of discovery
Symptoms owners cite: Brake fluid puddle on driveway or floor; Fluid completely drains after refilling; Low brake fluid warning light; Oily substance in engine compartment or on wheel rims
Repairs/costs cited: Brake hose replacement required; fluid refilling temporary solution only
Recalls/TSBs owners mention: Some cases qualify for recall repair under 23V162000 once parts available
Brake Light Switch Pad/Button Failure
Rubber grommet, bushing, or pad that activates the stop-light switch deteriorates and breaks apart, preventing brake lights from functioning or causing them to stay on constantly.
When: Reported at 40k miles and various other mileages; occurs in hot/humid climates
Symptoms owners cite: Brake lights constantly on; Brake lights do not function; Plastic pieces found on floor under pedal; Unable to engage vehicle out of park; Vehicle cannot accelerate past 35-40 mph (due to lights-on signal)
Repairs/costs cited: Replacement requires full brake pedal assembly purchase; costs $585+ including labor. Part breaks into pieces and is not available separately. Aftermarket retrofits required in some cases.
Recalls/TSBs owners mention: 2013-2015 models recalled; 2016 model not included despite same part design and failure mode
Rotor Wear and Improper Brake Assembly
Rotors worn completely off with missing brake components. One case involved improper initial assembly by dealership.
When: Few weeks after vehicle delivery in reported case
Symptoms owners cite: Horrible noise from brakes; Car doesn't stop immediately; Must slam pedal to ground to begin stopping; Black rims from brake dust; Vehicle difficult and unsafe to drive
Repairs/costs cited: Rotor replacement and brake system rebuild required; owner paying for parts damaged by improper assembly
Recalls/TSBs owners mention: Dealership denied responsibility; owner financing vehicle she cannot safely drive
Synthesized from 97 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
Our brake light came on spontaneously for several seconds while car sat idle with parking brake off (my spouse was in the car and saw this happen). We turned the parking brake on and off, but the light remained on. It went off after about minute by itself. We took the car into the dealer service center to check that issue and do an oil change. They did a "vehicle check-up" (we have the paperwork)…
The vehicle is a 2016 Ford Fusion with 70,000 miles when this happened happened the first time. I pushed on the brakes and the pedal went to the floor. I had just enough braking power to stop the vehicle. The danger is obvious, I had no brakes but I was going slow on local roads. I had the vehicle towed to an independent repair shop where they diagnosed failure of the right rear brake caliper.…
Had brakes trouble with your 2016 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 brakes problem on the 2016 Ford Fusion?
It's a meaningful issue. 97 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $450.
At what mileage does the brakes typically fail?
Across the 44 complaints that reported odometer mileage, most brakes failures cluster between 69,000 and 135,300 miles, with the median around 93,530. A quarter of owners report trouble before 69,000; a quarter make it past 135,300. 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 $450 for brakes 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 brakes?
No active recalls currently cover brakes 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/2016/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.