2016 Ford Fusion powertrain problems

The plastic bushing that connects the transmission shifter cable to the transmission degrades and detaches over time. When detached, the gear shifter can be moved to Park and the ignition key removed, but the transmission remains in a different gear—most commonly Neutral or Reverse. The dash display may show Park while the car is actually in Neutral or Reverse, creating a rollaway hazard.

When: Failures reported across all mileage ranges; some occurring years after recall repairs (e.g., #2 at 245,000 miles, 7 years after 2018 recall fix at 88,000 miles); others early in ownership (reported at 50k, 70k, 80k, 130k, 147k, 181k miles)

Symptoms owners cite: Shifter moves freely but transmission does not engage selected gear; Vehicle rolls backward or forward while shifter shows Park; Dash display shows one gear while transmission is in another; Shifter becomes stuck or very difficult to move between gears; No warning lights or chimes before failure; Orange plastic bushing debris visible (in some cases)

Repairs/costs cited: Replacement bushing kits cost $5–$7.64 for the part; labor and towing vary. Owner #2 bought updated yellow plastic bushings and cover for ~$250+ out-of-pocket after recall fix failed. Some dealers unable to perform repairs due to parts unavailability (Recalls 18V471000, 18S20, 19V362000, 22V413000). DIY fixes reported using universal bushings from auto parts stores.

Recalls/TSBs owners mention: Recall 18V471000 (July 2018) and 18S20 began Sept 2018 for 2013–2016 Fusions built at Hermosillo plant June 2, 2014–Aug 31, 2015. Later recalls 19V362000 and 22V413000 issued but do not cover all affected VINs; many owners report VINs excluded despite identical failures. Updated repair parts (yellow bushing + cover) developed for later recalls but not retrofitted to earlier repaired vehicles. Parts shortage delays repairs; some dealers told to repair only after car breaks down and is towed.

Engine power drops abruptly with no warning or only brief warning (wrench icon, 'See Manual' message). Accelerator pedal becomes unresponsive; pressing it has no effect. Vehicle cannot exceed 15–50 mph and loses power in traffic or at highway speeds. Electrical systems (steering, braking, climate, radio) remain functional. Power returns after restart, but failure recurs.

When: Reported from 12,000 miles to 105,000+ miles; some early in vehicle ownership (new purchase with <20k miles); recurring within days or weeks of repair attempt

Symptoms owners cite: Complete loss of engine power while driving, usually at highway speed (60–70 mph); Accelerator pedal will not respond—pressing it does nothing; Orange wrench light and 'See Manual' message appear on dash; Vehicle shakes, shudders, or vibrates during power loss; Speed drops to 15–50 mph maximum; cannot accelerate; Cruise control deactivates; traction control and other stability systems disabled; Check Engine light may illuminate; Power returns after restart; car may run normally until failure recurs

Codes mentioned: P0300 (cylinder misfire), P2112 (throttle actuator 'A' control system-stuck closed)

Repairs/costs cited: Dealers have replaced throttle body ($unknown labor cost), updated software, replaced fuel sensor. One owner reports dealership statement 'happens all the time – there was a bad batch.' Some repairs fail and power loss recurs within days or weeks.

Recalls/TSBs owners mention: No formal recall issued for throttle body failure, though a 'Customer Satisfaction Program' is referenced in complaint #20 and #26. TSB 19-2346 addresses coolant leak into cylinder (related but distinct). Ford has issued no recall for power loss despite multiple complaints and owner research indicating the problem is documented across many model years.

Transmission deteriorates prematurely, diagnosed as torque converter failure, defective bearings (HF35 hybrid models), shattered clutch, or general internal damage. Fluid often dark with metal filings or fragments. Transmissions fail as early as 77,000–100,000 miles despite proper maintenance. Repair or replacement costs $6,000–$9,500+.

When: Reported at 58k, 77k, 100k, 105k, 120k, 130k miles; one failure at 49k miles with shifting lunge

Symptoms owners cite: Vehicle stalls at low speed while starting or shifting; Harsh, jerky shifting between gears; Vehicle jerks or lurches when accelerating from stop or shifting; Transmission fluid dark or black with metal particles or filings; Whining noise from transmission (hybrid models); Check Engine light and wrench warning light illuminate; Failure to accelerate; loss of power during acceleration

Codes mentioned: Shift solenoid D (generic)

Repairs/costs cited: Full transmission replacement $6,000–$9,500. One owner reports dealer replaced only transmission fluid after stalling complaint, then a month later diagnosed need for complete transmission replacement due to metal filings in fluid. Rebuilds quoted as alternative. No warranty coverage for most owners.

Recalls/TSBs owners mention: No recall issued. Owner #3 notes Ford has known 2009–2017 Fusions have faulty transmissions and has offered 'band aid' recommendations but no compensation. A Customer Service Satisfaction Program 14B07 replaced transmissions for 2013–2014 Fusion Hybrids but expired; 2015–2016 hybrids with same bearing defect (TSBs 14-0214, 16-0105, 17-0039) receive no coverage.

Vehicle rolls forward or backward despite shifter being in Park position. Occurs while parked on level ground or slight inclines. In some cases, the transmission is actually in Neutral or Reverse but the display falsely shows Park. Hazard intensified when vehicle is parked unattended or with occupants still inside.

When: Multiple incidents reported; some within days of ownership, others after years of ownership

Symptoms owners cite: Vehicle rolls backward or forward while shifter is visibly in Park; No warning lights or chimes before rollaway begins; Dash display shows Park but transmission is in Neutral or Reverse; Emergency brake may be required to stop rolling

Repairs/costs cited: Caused by shifter cable bushing failure (see separate mode). Repairs as noted under bushing detachment.

Recalls/TSBs owners mention: Related to Recalls 18V471000, 18S20, 19V362000, and 22V413000. Many owners report recalls do not apply to their VIN despite identical failures.

Engine coolant leaks into one or more cylinders, causing white smoke from exhaust, rough idle, misfire, and eventual engine failure. Likely caused by crack in engine block or failed gasket. Requires engine replacement.

When: Reported at 75,000 miles and in early ownership (owner #13 at unknown mileage; owner #37 at 75k)

Symptoms owners cite: White smoke billowing from exhaust, especially on startup or idle; Rough idle and stalling shortly after startup; Check Engine light illuminates (P0300 cylinder misfire code); Engine dies during normal driving; Coolant level drops; coolant may spout from reservoir

Codes mentioned: P0300 (cylinder misfire)

Repairs/costs cited: Engine replacement quoted at $7,300. TSB 19-2346 addresses the issue but does not cover the repair cost; only owners with extended warranty may get coverage.

Recalls/TSBs owners mention: TSB 19-2346 issued but no recall. Owner must pay full cost unless extended warranty covers it.

Ignition key is extremely sensitive; barely rotating the key back (not far enough to turn off the engine) causes the engine to cut out and display 'Transmission Not in Park' error message, even though the transmission is in Park. This can occur at highway speeds, especially if the key is bumped or jostled.

When: Reported at 48,000 miles; recurred three times over several months

Symptoms owners cite: Engine power loss at highway speed (60+ mph); 'Transmission Not in Park' message appears on dash; Engine must be restarted to regain power; Failure can be triggered by bumping ignition key with knee or leg

Repairs/costs cited: Ford dealer determined replacing ignition switch would not fix the problem, as multiple 2016 Fusions exhibit the same behavior. Suggested using parking brake until recall remedy is available.

Recalls/TSBs owners mention: Ford has not issued a recall. Dealers acknowledge other Fusions have the same issue but consider it normal behavior, not a defect.

Engine overheats due to thermostat or engine block crack. Antifreeze and water spurt from reservoir. Engine temperature gauge moves to hot, and 'Power Reduced to Lower Engine Temp' warning appears. Vehicle may cut out on highway with check engine light. After repair, overheating recurs.

When: Reported at 73,000 miles on used purchase; overheating incidents on March 12, 22, 24, and April 11

Symptoms owners cite: Engine overheating; temperature gauge moves to H; Antifreeze and water spurt from reservoir; 'Power Reduced to Lower Engine Temp' message on dashboard; Vehicle loses power on highway; check engine light illuminates; Blunt sound from vehicle before power loss

Codes mentioned: Fuel system code (unspecified)

Repairs/costs cited: Initial repairs included thermostat and thermostat housing replacement at Pep Boys (5 days labor), and tube assembly replacement at independent shop. Overheating recurred within weeks despite repairs.

Recalls/TSBs owners mention: No recall mentioned; customer was directed to independent repair shops rather than Ford dealer.