The EV Range after fully charging a Focus Electric, C-MAX/Fusion Energi may vary after each charge event. The window sticker indicates 0-20 mile range for C-MAX Energi, 0-21 mile range for Fusion Energi. Variation of EV range may not indicate a battery or charging concern. EV range is similar to the DTE display on gasoline vehicles, EV range will vary with driving/operating conditions. Conditions include: extreme outside temperatures, terrain, driving style, city or highway driving, tire pressure, and use of accessories. If the customer replaces the low roll resistance tires with a more aggressive tread the range will suffer. Using the cabin heater and A/C, which are electric, will also decr
full bulletin at NHTSA ↗2017 Ford Fusion wheels problems
moderate Owners of the 2017 Ford Fusion have filed 21 NHTSA complaints about the wheels, typically surfacing around 45,000 miles at roughly $400 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See wheels across all vehicles →
Failure mileage
Complaints
21
Recalls
0
Avg fix
$400
| Model year | wheels complaints |
|---|---|
| 2013 Fusion | 27 |
| 2014 Fusion | 32 |
| 2015 Fusion | 19 |
| 2016 Fusion | 42 |
| 2017 Fusion (this page) | 21 |
| 2018 Fusion | 11 |
| 2020 Fusion | 3 |
1crash
What stands out
No new NHTSA wheels complaint has been filed on this vehicle in over 4 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 wheels 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.
Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2017 Ford Fusions consistently report that lug nuts swell and become impossible to remove, typically between 16,000 and 71,000 miles. The problem stems from a two-piece lug nut design with a chrome cap that expands under friction and heat during normal driving. Standard 19mm sockets and factory-provided lug wrenches no longer fit, preventing tire rotations, repairs, and emergency tire changes on the roadside.
Dealers inform owners that all 20 lug nuts (five per wheel) require replacement with single-piece units, at owner expense ranging from $100 to $300+ including labor. Multiple owners report the outer chrome casing separates or bulges, and one owner noted this same problem occurred on their 2011 Fusion, suggesting a systemic design issue. Dealers have explicitly warned some owners that swollen lug nuts risk shearing or breaking during driving, potentially causing wheel detachment and loss of control.
While Ford appears to be aware of the problem—some owners report dealers calling it a "known issue"—no recall has been issued. Owners express frustration that Ford created the defect yet refuses to cover replacement costs.
Same Ford Fusion wheels reports on nearby years: 2014 · 2015 · 2016 · 2018
Failure modes owners describe
Swollen lug nuts (chrome-capped design)
Lug nuts with a two-piece chrome-capped design swell due to friction and heat during normal driving. The outer chrome cap separates or expands, making the lug nuts too large to fit standard sockets and lug wrenches. Owners cannot remove wheels for tire changes, rotations, or repairs. Dealers report this is a known issue affecting all four wheels (20 lug nuts total per vehicle).
When: 16,000 miles to 71,000 miles; most complaints cluster between 30,000–57,000 miles
Symptoms owners cite: Lug nuts unable to be removed with factory-provided or standard 19mm lug wrenches; Chrome cap on lug nut swells or separates; Wheels cannot be rotated or removed during maintenance or roadside emergencies; Shaking or vibration while driving (one report); Difficulty or impossibility of tire changes in emergency situations
Repairs/costs cited: Dealers replace all lug nuts (typically 20 total) with single-piece lug nuts. Owner costs cited: $100–$300+ including labor. One owner reported $219.80 for all 20 lug nuts.
Recalls/TSBs owners mention: Owners report Ford was notified in some cases but provided no assistance or recall. Narrative #15 mentions the contact took vehicle in for NHTSA Campaign 23V162000 (brake-related recall). One narrative (#8) states contact was notified the failure was a 'known issue.'
Lug nut failure risk leading to wheel detachment
Dealers have advised owners that swollen lug nuts could potentially shear off or break entirely during driving. If lug nuts fail completely, wheels may detach, causing loss of vehicle control. Owners report dealers explicitly warned of this worst-case scenario.
When: Potential failure mode identified during routine maintenance; no specific failure mileage provided for actual detachment
Symptoms owners cite: Dealer warning of potential wheel detachment; Risk of load shifting to remaining lug nuts if one breaks; Potential loss of vehicle control
Repairs/costs cited: Preventive replacement of all lug nuts recommended by dealers before failure occurs.
Synthesized from 21 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Swollen lug nuts that can’t be removed because they have swollen to be too large for the included jack as well as any other 19mm socket. My 2011 fusion had this problem and I spent approx $200+ to fix for all wheels inc labor (was labor intensive to strip off outer casing of swollen lugs), now my 2017 fusion has the same issue and I cannot out on a spare to replace my completely flat tire- will…
Had wheels trouble with your 2017 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 wheels problem on the 2017 Ford Fusion?
It's a documented issue but not catastrophic. 21 complaints have been filed. Repairs average $400 and most owners catch it before it causes a breakdown.
At what mileage does the wheels typically fail?
Across the 13 complaints that reported odometer mileage, most wheels failures cluster between 36,000 and 54,042 miles, with the median around 45,000. A quarter of owners report trouble before 36,000; a quarter make it past 54,042. 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 $400 for wheels 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 wheels?
No active recalls currently cover wheels 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/2017/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.