The contact's daughter owns a 2015 Ford Fusion. The contact stated that while her daughter was driving at various speeds, the vehicle experience random engine misfire. The vehicle was taken to gulf coast Ford (3000 N, state hwy 288, angleton, tx 77515) and diagnosed with a defective head gasket. Her daughter was informed that the engine needed to be replaced. The manufacturer was made aware of the failure and a complaint was filed. The vehicle was not repaired. The failure mileage was approximately 134,000.

- Brazoria, TX, USA

I sent the following letter to other agencies as well but wanted to send it to you. Since I sent the letter I have found that my problem has happened to a bunch of other Ford Fusion owners where the gasket goes bad and fluids leak into the cylinder and ruins the engine. It seems like there's a flaw in my engine model. I have an ecoboost engine and from what I was reading on carcomplaints.com there's been a bunch of people that have the same problem with their car. I'm going to copy and paste the letter I sent to you earlier today. Any help you can give me would be much appreciated. I have a 2015 Ford Fusion that I purchased new from gold mill Ford in niles, il and have all of my maintenance done at the dealer. The car only has 33 thousand miles on it and I purchased the car new from the dealer in April of 2015. The warranty just expired on April 13, 2020 and on May 19, 2020 the service engine soon light came on and I took it to the dealer. I had just brought the car in for an oil change at the dealer on May 4th 2020. I lost my job and with all the covid 19 stuff going on I never got an extended warranty. I put my insurance on the car on hold May 26, 2020 cause I wasn't going to be driving it with the covid 19 stuff. I'm not sure if they forgot to put a cap on something at the May 4th oil change or something but all I know is the car was running perfect before I brought it in for the oil change and now I'm stuck with a car that they say needs over $5030 and tax worth of repairs. I tried to get help from the Ford assistance program but they denied me any help. I was wondering if you could help me out cause I don't have $5,030 plus tax to fix the engine. What would be my options to getting help? I hope someone can help me figure out this mess and get some help. Thank you for your time in reading my story. Sincerely, [xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Des Plaines, IL, USA

My 2015 Fusion had intermittent rough idles and the check engine light popped on. I checked out the code and it was P0301 - misfire in cylinder 1. I took it to the local Ford dealer ' penske Ford in la mesa, ca - for inspection. The service advisor had his team pressure test and boroscope the engine and found coolant residue in cylinder 1. he said that they checked for the fix to the issue and found a service bulletin about it (I found it on NHTSA website ' bulletin 20-2100), which directed them to replace the short-block - $7,000 ish dollars to fix. With just a small amount of research I discovered that this is a problem many Ford owners are having right now with this engine - 1.5L I4 F DOHC 16V. There is even an exploratory class-action lawsuit being formulated around this engine issue (https://www.newsom.law/Ford-Fusion-overheating-lawsuit.html), so it is a known problem. Service advisor said that pitting on the short block is the likely cause and that is why Ford has said to solve the problem, the short block needs to be replaced. Less than 5 years old, living in a mild climate, and the block is pitting. I contacted Ford through their online chat and through the phone and they were unable to assist me short of saying that there are no recalls issued for this obvious manufacturing defect, so there is no issue on their part. They said NHTSA has to issue a recall before they will do anything out of their pocket. Attached documents include: Transcript from online chat to Ford links to my research including example of cases on the NHTSA website with the same issue for the same car letter I am sending to Ford invoice from Ford dealer where issue is noted and sb 20-2100 is noted the Ford service bulletin referenced - 20-2100

- San Diego, CA, USA

The contact owns a 2015 Ford Fusion. The contact stated the check engine warning light was illuminated. The diagnostic trouble code indicated a misfire on cylinder #1. the contact stated that the vehicle shuddered while driving with an abnormal knocking sound coming from the engine. The vehicle was taken to Ford of tuscola, Inc (406 E southline rd, tuscola, il 61953, (217) 253-3353) to be diagnosed. The contact was informed that coolant leaked into the cylinder and that the engine block needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and informed the contact that the repair was not covered under warranty or a recall. A case was filed. The approximate failure mileage was 55,000.

- Lexington, NE, USA

The contact owns a 2015 Ford Fusion. The contact stated that at start-up, there was an engine misfire with the check engine warning light illuminated. The vehicle was taken to an independent and the spark plugs were replaced. One month after the spark plugs were replaced the failure recurred. The vehicle was then taken to a second independent mechanic where the spark plugs were replaced a second time however, the failure recurred. The vehicle was taken to a third independent mechanic where spark plug number 4 was replaced however, the failure persisted. The vehicle was then taken to ruxer Ford Lincoln, Inc. (123 place rd, jasper, in 47546, (812)482-1200) to be diagnosed. The contact was informed that there was a hairline fracture on the engine block. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure and informed the contact that the vehicle warranty was expired. The failure mileage was 43,000.

- Ireland, IN, USA

Bought used in Feb 2019. In July of same year it was diagnosed blown head gasket cyl 2. out of warranty so had to pay $3,100 to replace. Now, 9 months later, same thing cylinder 2. in December of 2019 Ford came out with bulletin tsb 19-2375 stating the block needs replaced to solve this problem. That is an over $6,000 repair. I call that a defective block which should warrant a recall, Ford simply told me it's called out of warranty and it's my problem. My problem is, it's my only form of transportation. So what it is doing is when I start it, it runs rough because it is misfiring do to coolant leak into the cylinder and white smoke comes out of exhaust. It is my belief that Ford knows this is a defective block otherwise they would not have issued the bulletin. An internet search will show many other owners of the 2014 through 2019 produced 1.5 liter motors have the same problem. I tried to upload the repair bill and the tsb bulletin but it stated file too big.

- Reeds Spring, MO, USA

Coolant leak. Vehicle serviced 3 weeks ago, and coolant is constantly leaking causing engine to overheat. This has happen twice since vehicle was serviced.

- Centralia, IL, USA

The contact owns a 2015 Ford Fusion. The contact stated that when the vehicle was started, the vehicle shook violently and misfired. The vehicle was taken to allan jay Ford Lincoln (3201 us hwy 27S, sebring, fl 33870), where it was determined that the cylinder number two was defective. The contact was informed that the engine needed to be replaced. The manufacturer was notified of the failure. The vehicle was not repaired. The approximate failure mileage was 140,000.

- Lake Placid, FL, USA

The contact owns a 2015 Ford Fusion. Contact stated that while driving at various speeds, the engine and air bag warning lights illuminated. The vehicle loss motive power and acceleration. The contact drove the vehicle back to the residence. The vehicle was taken to mel hambelton Ford, Inc, (11771 w kellogg dr, wichita, ks 67209, (888) 489-1719) to be diagnosed. The contact was informed that the coolant was pressed into the cylinder and the engine needed to be replaced. The vehicle was not repaired. The failure recurred. The manufacturer was contacted and informed of the failure. The failure mileage was approximately 140,000.

- Witchtal, KS, USA

Ford Fusion having a coolant leak into the engine. I've heard from multiple people having the same issue & now I'm having the same problem after only having my Fusion for two years & still making payments. Car makes a sloshing noise in dashboard when accelerating, turning or braking & car overheats due to coolant leaking into engine & having to constantly refill coolant.

- Tallahassee, FL, USA

Has problems starting after putting gas in the tank. Check engine light on, mechanic says it's a purge valve. Know alot of other Fusion owners with same problem. Seems to be happening around 40,000 miles. Have to sit at gas station about 10 to 15 min sometimes. Others times just starts rough.

- Alliance, OH, USA

In Oct. 2019 I bought a 2015 Ford Fusion SE with 65K miles on it. Since then I have put 4K miles on it. On 3/17/20 my car started cutting out and the service engine soon light came on. I drove it 1/2 mile to the nearest store and called my friend to bring his car code reader. It was showing a misfire on cylinder 2. went and got a spark plug and new coil pack and put on it. The car was running rough and was still showing a misfire on cylinder 2. had the car towed to a repair shop in prattville, al. To see why it was still showing a misfire on cylinder 2. I was told that there was a crack in the head around cylinder 2. I called riverside Chevrolet in wetumpka, al because that is where I bought the car. The called collier Ford in wetumpka, al because of the low miles on it to see if they could look at it for me and possible help me out with the cost. I had it towed to collier Ford and was told that the block is cracked and that the service manager at collier Ford and the general manager at riverside Chevrolet was in contact with Ford to see if they can get this resolved for me. As of today 3/25/20 I still don't have an answer as to if Ford is going to replace my motor. I noticed after doing research that this is an common problem. I don't understand why this hasn't become a recall yet. Ford needs to stand behind there product.

- Prattville, AL, USA

Spark plugs continue to foul causing antifreeze to leak into engine resulting in needing a engine replacement. Been told I need a brand new engine on a 5 year old car.

- Chapel Hill, NC, USA

I began to hear a scrapping noise in the engine compartment. I took the car to have the oil changed and was told that I needed to have the transmission fluid changed and it was a closed system and only Ford would be able to do this. I took my car to knox Ford where I purchased it and had them change the transmission fluid and diagnose the problem. I was told that the water pump was bad and needed replaced. After investigating I found that this was timing driven and again only Ford could do this repair. I took the car in the night before and they quoted me $672 for the repair. I was told this would take 4.5 hours to complete. At 5pm the following day I picked up my vehicle only to find out they had just finished it. I was told then that it took longer because the original water pump was discontinued because Ford knew the part was bad. They continued to tell me that they had to research how to cut the wires that were no longer needed and install the new water pump. V

- Radcliff, KY, USA

Vehicle has 100,215 miles and is 5 years old mid January 2020 check engine light came on. Code 303 - cylinder 3 misfire. Changed spark plugs. Same code. Had vehicle checked by private mechanic. Coolant located in cylinder 3. case started with Ford Motor Co. Vehicle taken to Ford dealership where it was orginally purchased. After adding dye to the coolant they verified the cylinder #3 leak. They reccomend an engine replacement - $6550.20. They offered to buy vehicle from us for $1500. Oh, and I should mention that the vehicle was officially paid off one week before the check engine light came on and this all started. See attached invoice from February 2020

- Lakewood, OH, USA

On 10/7/2019 I brought my car in to fort mill Ford (SC) for a tire change and regular service. When I came to pick it up on 10/10/2019, the car would not start. Upon advising my tech brittany of the issue, they sent out a tech to jump start the car that was just serviced. When the car was jump started, an engine light appeared on the dashboard. The vehicle was at 62000 miles. I went back to my adviser brittany again and she stated that the engine light is nothing to worry about and that Ford activates those when seasons change and is part of their software. She insisted that everything was ok with the car and referenced the inspection list I was given for my 2015 Ford Fusion SE. Not three weeks later, the engine light went from being constantly on, to flashing. This also caused an intense white smoke from the exhaust and a strong gas presence in the vehicle. While I was driving to work, the engine light started flashing and the car started jerking on I-77 highway. I took the car back to fort mill Ford on 11/18/2019 for inspection. The next day, brittany called me and said they found an issue with my spark-plug and that it might cost anywhere from $200 to $6000 to repair it. Since the issue was not caused by me I was not going to take responsibility for the charges and after weeks of ignoring me, Ford Motor Company (office of elena Ford) decided to get involved. However, the cause went from spark-plugs to coolants then cylinders and I was never given a specific cause. I did not have my car for over 60 days because all parts were on back order. I got my car back on 1/21/2020 and it is still showing issues with acceleration. Out of 91 NHTSA complaints on engine issues, over 31 have these same symptoms. Please see attached documents detailing this issue. This form does not offer enough space for relevant information and I was not able to upload the last email thread.

- Fort Mill, SC, USA

My check engine light came on and it indicated low coolant and misfire in cylinder 4. I had a coolant leak into cylinder 4 in my engine at approx 69,000 miles and was advised I needed a new engine block... their were 3 other cars at the dealership with the exact same issue. I was told it would cost approx 7500... after complaining to service dept they opened a case with Ford and they agreed to do it for approx 2500 as it was just out of 60,000 warranty and just over 3 years old. Service advisor said Ford had a known issue with head gasket apparently moving and wearing out which caused the issue. Approx 8 months later exact same issue and I needed another engine change. This time the dealership had 7 cars in shop with same issue waiting on engine changes.again was told Ford has issues w head gasket moving and wearing out gasket allowing coolant to leak into cylinder. Supposedly Ford has upgraded their gaskets and other parts to correct issue but I dont believe the customers should bear responsibility when Ford has known issue that costs customers such a big amount. I know it was just past orig warranty but this is a Ford engineering problem that customers and bearing brunt of costs. The second engine change was covered under warranty but im concerned about it happening again or the loss of value from 2 engine changes in less than 80K miles. The date entered below is an estimate. Engine was changed twice in 2019 and less than 10K miles in between.

- Kansas City, MO, USA

The contact owns a 2015 Ford Fusion. The contact stated that upon starting her vehicle, the vehicle began smoking from the tailpipe and was emitting a gas odor. The contact was unaware if any warning lights illuminated on the vehicle. The contact had the vehicle towed to tindol Ford located at 1901 E franklin blvd, gastonia, nc 28054 where the vehicle was diagnosed with a defective injector which caused the fuel to seep through the injector and mix with the oil, causing the failure. The vehicle had not been repaired after the diagnosis. The manufacturer had been notified of the failure. The failure mileage was approximately 60,000.

- Charlotte, NC, USA

The contact owns a 2015 Ford Fusion. The contact stated that while driving at high speeds, there was an abnormal sound coming from the fuel tank. While the vehicle was stopped, the vehicle stalled. The contact was able to restart the vehicle after several attempts however, the check engine warning light was illuminated. The vehicle was taken to ed butts Ford (1515 N hacienda blvd, la puente, ca 91744, (800) 960-3673) but was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was unknown.

- La Puente, CA, USA

The contact owns a 2015 Ford Fusion. The contact stated that the vehicle exhibited multiple failures. The vehicle lost power independently and the brake pedal failed to engage while driving. Also, after fueling the vehicle, the engine failed to start. Furthermore, when the accelerator pedal was depressed, the vehicle would not accelerate. The vehicle was taken to elk grove Ford (9645 auto center drive, elk grove, ca 95757, (916) 478-7000) where it was determined that the windshield wiper fluid penetrated the brake fluid. The brake lines, calipers, and the battery were replaced twice; however, the repairs did not correct the failures and the vehicle continued to stall. The vehicle was taken back to the dealer, but they could not duplicate the failures. The manufacturer was not contacted. The vehicle was not repaired. The failure mileage was not available.

- Elk Grove, CA, USA