2016 Ford Fusion electrical problems

Coolant and oil leak into engine cylinders due to internal gasket/seal failure, causing misfire, overheating, white exhaust smoke, rough idle, and eventual engine shutdown or stall.

When: Typically within 3–6 years of ownership; some owners report symptoms starting at 2,500–69,000 miles.

Symptoms owners cite: White exhaust smoke; Low coolant level requiring frequent top-offs; Oil burning smell and coolant smell from engine bay; Engine overheating and temperature warning; Rough idle and shaking; Cylinder misfire and check engine light (codes P0300, P0301–P0304, P0316, P0217, P1285, P1299); Lack of power and stalling while driving; Coolant pooling inside cylinders visible on borescope inspection

Codes mentioned: P0300, P0301, P0302, P0303, P0304, P0316, P0217, P1285, P1299

Repairs/costs cited: Owners cite turbo drain tube replacement ($), valve cover gasket replacement, and short-block replacement with head gasket. One owner reported $800+ for engine work; Ford TSB 20-2100 directs replacement of short block and head gasket.

Recalls/TSBs owners mention: TSB 20-2100 (April 2020) covers 2014–2019 Fusion with 1.5L EcoBoost built on or before 10-Jun-2019. Some owners were excluded from recalls despite having identical symptoms and engine codes. One owner stated Ford refused to add their VIN to the recall list.

Electronic throttle body intermittently fails or sticks, causing sudden loss of power and engine stall—often on warm restarts (shortly after turning vehicle back on) or at highway speed without warning.

When: Typically 2–7 years into ownership; failures reported at various mileages with no clear pattern.

Symptoms owners cite: Engine stalls when accelerating or maintaining highway speed (65–75 mph); Stall immediately after warm restart (within 30 minutes of shutdown); Low idle (500 RPM instead of normal 1000 RPM); Wrench icon and check engine light (sometimes intermittently or not at all); Shuddering and shaking when power loss occurs; Vehicle won't accelerate past 2,500 RPM before dying; Stall during deceleration in parking lots

Codes mentioned: P0300, No code (intermittent faults often do not store)

Repairs/costs cited: Throttle body replacement cited by owners; turbocharger replacement also mentioned. Repair costs not always specified but dealership service advised.

Recalls/TSBs owners mention: Ford aware of throttle body issues but some owners state no recall exists for their VIN. Dealers often unable or unwilling to diagnose unless vehicle exhibits fault during their test drive.

The Accessory Protocol Interface Module (APIM) and/or the broader electrical system reboots or shuts down unpredictably while driving, disabling infotainment, safety systems, and vehicle controls. Complete electrical blackouts reported.

When: As early as 2–3 years; one owner reported issue within 2 weeks of purchase. Failures may occur intermittently over months or years.

Symptoms owners cite: Entire dashboard goes dark; all lights and displays shut off; Backup camera display blackout; Radio and air conditioning shut off mid-drive, then restart on their own; Touchscreen unresponsive or flickering; Power steering fails; Power windows and door locks inoperable; Safety systems offline (ABS, airbags, collision avoidance, adaptive cruise control); Climate control and heated seats fail; Windshield wipers turn on without input; Cross-traffic and blind-spot system fault warnings appear intermittently; Steering becomes very tight or difficult to turn; Brake pedal stiffens and becomes hard to push; Engine check lights and multiple warning codes illuminated, sometimes clearing after restart

Codes mentioned: Multiple codes often stored simultaneously; diagnostic scanners report 'so many codes they don't know where to start', Specific codes vary but may include body control module (BCM) or power distribution faults

Repairs/costs cited: One owner cited wiring harness under driver seat as likely culprit; another reported $4,000 for wiring harness replacement. Dealer diagnostics often inconclusive. One owner replaced motherboard/APIM at dealership cost (amount not specified); issue recurred.

Recalls/TSBs owners mention: NHTSA Campaign 15V406000 addresses APIM issues on other Ford models. Owners report dealerships perform software updates (sometimes free, sometimes not), but updates often fail to install. One owner stated Ford's software update would not properly install and the dealership quoted $700 for a replacement APIM + $600 labor, with no manufacturer assistance offered.

Trunk pops open spontaneously while parked or driving; door latches fail to secure. Both incidents involve electrical malfunction in the locking/unlatching mechanism.

When: One owner reported trunk popping for first few weeks, stopping, then recurring in spring and again in fall. Door latch failures reported at various mileages without clear pattern.

Symptoms owners cite: Trunk pops open while parked, especially in warm weather; Trunk opens while vehicle is being driven; Trunk release mechanism clicks continuously after popping open; Door latches fail to catch; drivers can open locked doors; Doors unlock themselves mid-drive; Keypad lights flicker on and off; Battery drains overnight due to continuous lock/unlock cycling

Repairs/costs cited: One owner replaced battery ($) thinking it was drained; issue persisted. Door latch repairs performed at owner expense (amounts not specified).

Recalls/TSBs owners mention: One owner stated ford dealership had never heard of the problem despite multiple consumer reports online. Similar issues reported on multiple 2016 Fusion vehicles without recall action.

Rearview camera display shows black screen or no image when vehicle is placed in reverse, creating a safety hazard. Failures are sometimes intermittent.

When: Owners report failures from early ownership to 105,000+ miles; some cameras fail intermittently, others completely.

Symptoms owners cite: Black screen when reversing; No image displayed on infotainment screen; Camera worked previously, then stopped; Intermittent failures—sometimes camera works, sometimes does not

Repairs/costs cited: One owner quoted $800 for new camera but dealer offered $500 repair (unclear what was involved). Another owner mentioned warranty denial.

Recalls/TSBs owners mention: One owner stated dealership said the camera failure was not covered under warranty. Some owners cite similar issues in other Ford models and suspect the problem predates Ford's acknowledgment.

The clock spring in the steering wheel fails, causing loss of steering wheel controls (cruise control, volume, button input) and potentially affecting airbag deployment.

When: Reported at 2–3 years of ownership in some cases; timing varies.

Symptoms owners cite: Steering wheel buttons (cruise control, radio volume) stop working; Dashboard lights flicker when opening door; Potential concern about airbag non-deployment (not confirmed in these complaints but cited as risk)

Repairs/costs cited: One owner self-replaced clock spring after purchasing one online. Ford dealership did not perform the repair for the owner; one owner stated they were not offered the fix.

Recalls/TSBs owners mention: Clock spring recalls exist for some 2016 Ford trucks but 2016 Fusion was not included despite using the same parts. One owner stated Ford Customer Service acknowledged the steering wheel issue but did not offer a recall or repair.

The connector to the SCME module melts due to insufficient grounding on the module, causing overcurrent and fire risk. Heated and cooled seats fail as a result.

When: Owner did not specify exact timing.

Symptoms owners cite: Both front heated and cooled seats stop working; Connector visibly burned and melted; Seat control functions inoperative

Repairs/costs cited: Dealer quoted $596.11 for new SCME module and burned connector replacement. Owner self-repaired by replacing connector and adding a second ground wire to the SCME module.

Recalls/TSBs owners mention: None mentioned; owner identified and fixed the root cause (inadequate grounding) themselves.

Horn activates on its own without driver input, especially in warm weather or while driving. Diagnostic reveals faulty electrical wiring affecting ignition and airbag circuits.

When: Owner reported issue starting approximately two weeks before Memorial Day 2019 and continuing through the time of complaint.

Symptoms owners cite: Horn blares loudly without driver input; Occurs while backing up, turning, or parked in driveway; Happens in warm weather and during motion; Horn cycles on and off, causing community disturbance

Repairs/costs cited: Dealership disabled horn temporarily pending diagnosis; no final repair noted in complaint.

Recalls/TSBs owners mention: Diagnostic revealed faulty electrical wiring affecting ignition and airbag circuits. No recall or repair program mentioned.

Windows drop on their own while vehicle is parked; door locks fail to engage even when lock button is pressed. Child safety locks do not function as intended.

When: Reported at various ownership durations; one instance on first occurrence, others intermittent over time.

Symptoms owners cite: All four windows drop while vehicle is parked overnight; Windows roll down even when lock button is activated; Door locks unlock themselves mid-drive; Locks fail to engage despite pressing lock button; Child safety lock bypassed; child able to open 'locked' door from inside while vehicle running

Repairs/costs cited: No repairs documented; owners report multiple instances without resolution.

Recalls/TSBs owners mention: No manufacturer response documented; owners found similar complaints online but no recall issued.

Vehicle engine caught fire and was completely engulfed shortly after engine recall repair was performed. Dealership denied responsibility and refused to cover rental costs initially.

When: June 1, 2020, approximately 3 days after recall service (engine removal and replacement).

Symptoms owners cite: Engine spontaneously caught fire while driving on highway; Cabin filled with smoke; Vehicle completely engulfed and totaled

Repairs/costs cited: Engine was removed and replaced as part of recall (dates: May 26–28, 2020). No further mechanical details provided.

Recalls/TSBs owners mention: Koons Ford promised to 'shrink wrap' vehicle and investigate cause, then told insurance company they did not cause the fire. Refused to initially pay for rental car (later relented after owner pushed back). Ford Customer Service made promises but did not follow up.

A warning message appears stating 'Transmission Not In Park' or similar, causing the vehicle to lose acceleration power mid-drive. Typically occurs on highway at speed. Restarting the engine clears the message temporarily.

When: Reported as recurring issue over approximately 2 years; one owner reported approximately 5 incidents over a few months.

Symptoms owners cite: Warning message on dash: 'Transmission Not In Park' or similar phrasing; Acceleration stops; vehicle loses all power output; Occurs without warning while on highway at 65–75 mph; Engine doesn't stall but becomes unresponsive; Restarting engine clears message and restores power temporarily

Repairs/costs cited: No repairs documented; dealerships unable to diagnose. One owner reported a different dealership claimed a radiator was the issue; another dealership disagreed.

Recalls/TSBs owners mention: One owner stated a Ford dealership mentioned a recall exists but their VIN does not fall within the recall range.

Vehicle loses power or stalls unexpectedly while driving (especially on remote/highway roads at night). Initial diagnosis points to fuel pump failure; replacement does not resolve the issue, suggesting underlying electrical or sensor problem.

When: Failures occur intermittently without clear pattern.

Symptoms owners cite: Vehicle suddenly loses all power and shuts off while driving at highway speed; Orange wrench light illuminates; Instrument panel displays 'SEE OWNERS MANUAL'; Car shudders and shakes before shutdown; Engine restarts after a few cranks; Tire Pressure FAULT warning also appears

Repairs/costs cited: First fuel pump replacement cost $810 (labor included). Second fuel pump replacement performed at no charge 3 weeks later, suggesting the first diagnosis was incorrect or incomplete. Owner still experienced stalling after second pump.

Recalls/TSBs owners mention: Dealership advised owner is 'at their mercy' and charged for first diagnosis/repair even though issue recurred. No manufacturer outreach or lemon law buyback offered despite owner's threat of legal action.

While plugged in to charge EV battery overnight (no key in ignition, vehicle off), the engine spontaneously started and ran until out of gas in a closed garage, creating carbon monoxide poisoning risk.

When: Single incident; owner did not specify date.

Symptoms owners cite: Engine starts and runs without driver input or key in ignition; Vehicle plugged in to charge hybrid battery, in closed garage overnight; Engine runs to depletion; 12V engine battery becomes depleted and may have burned up (owner's speculation based on smell)

Repairs/costs cited: Owner suspects 12V battery replacement will resolve the issue (cost estimated under $1,000, though dealer quoted $1,000). Owner did not perform repair; vehicle remains out of service.

Recalls/TSBs owners mention: No manufacturer response documented.

ABS activates on dry ground during normal driving, causing brake pedal to become hard, pulsate, and require extended stopping distance. Root cause is a corroded wheel speed sensor harness (yellow wire with hole allows corrosion).

When: Recurring since mid-November 2018.

Symptoms owners cite: ABS activates on dry roads without cause; Service AdvanceTrac light illuminates on dash after 40 mph; Brake pedal becomes hard and drops approximately 50%; Stopping distance dramatically increases; Pedal pulsates under foot; Traction control turns off; hill assist turns off

Repairs/costs cited: Owner reports the tone ring (part of wheel bearing) is identified as the defective part, which is very expensive to repair.

Recalls/TSBs owners mention: Ford aware of the electrical harness issue (yellow wire corrosion on left front wheel speed sensor harness) but refuses to address it. Owner states Ford is unwilling to take responsibility.

Vehicle stalls unexpectedly and multiple times; check engine light flashes intermittently as the failure progresses but does not remain illuminated, preventing dealer diagnosis.

When: Stalling begins at unknown time; difficulty starting reported after refueling.

Symptoms owners cite: Stalling without warning; Difficulty starting after refueling; Check engine light flashes intermittently but does not remain on; No diagnostic codes stored

Repairs/costs cited: No repairs documented; dealership (Hennessy Ford Lincoln Atlanta) was notified but no repairs completed.

Recalls/TSBs owners mention: Manufacturer issued 25 TSBs for electrical systems and 16 TSBs for engine/cooling but no recall was open for the vehicle.

Radio, air conditioning, and window controls become inoperable intermittently while driving or at rest. Failures self-resolve after allowing vehicle to idle.

When: Intermittent; timing and frequency not specified.

Symptoms owners cite: Radio becomes inoperative; Air conditioning shuts off; Window switch locks independently without warning; Issue self-resolves after allowing vehicle to idle

Repairs/costs cited: No repairs completed; dealership unable to duplicate the failure.

Recalls/TSBs owners mention: Manufacturer not notified; dealership unable to provide diagnosis.

Engine exhibits low compression on all cylinders with normal oil color and full, clean coolant. Vehicle won't start reliably; oil and coolant levels are normal but compression is lost.

When: Timing not specified; vehicle purchased used with unknown history.

Symptoms owners cite: Vehicle won't start reliably; requires jump service; Diagnostic shows low compression on all cylinders; Check engine light always illuminates after repairs attempted; Engine overheating and loss of power

Repairs/costs cited: Mechanic shop advised engine replacement. Warranty denied coverage for parts like cylinder head gasket.

Recalls/TSBs owners mention: No manufacturer response documented; warranty does not cover engine work.

Rearview camera stops functioning immediately after routine dealership service (oil change, tire rotation, fluid top-off), suggesting service-related damage or disconnection.

When: Failure occurred immediately after service visit; camera worked fine for years prior.

Symptoms owners cite: No image displayed on rearview camera; Camera worked fine before service; Camera displays blanks or distorted image

Repairs/costs cited: Dealer quoted $800 for new camera but offered $500 repair (reason for discrepancy unclear); owner believes service caused the failure.

Recalls/TSBs owners mention: Dealership denied that service caused the failure. Similar camera issues noted in other Ford recall campaigns, suggesting potential pattern.