Coolant leaked into a cylinder due to a failed head gasket at 61,000 miles. Ford replaced head gasket, but the issue is due to poorly manufactured engine, and I had the same issue starting again at 99,000 miles. Ford refuses to fix engine since it is out of warranty, but the issue is due to poor manufacturing, not customer negligence.

- West Hartford , CT, USA

There is a " design flaw" with the vehicle where coolant leaks into the cylinder heads and you have to replace the whole engine. I have read about it in the Internet when my check engine light came on and gave me cylinder 2 misfire code.I started the car and the check engine light was off. I tried to get to work that morning and the car shut off on the middle of Interstate 81 with no warning. It was a very dangerous situation where I got stuck until it came to a complete stop and turn it back on. White smoke poured out of the tail pipe, I went home. I spoke with a Ford representative who said it is a design flaw in this engine and the whole thing needs to be replaced, with engines starting at $5,000 plus 4 days labor. He advised that the problem could happen again with the replacement. I know there is nothing you guys can do but my car died in 2 days.i have a $20,000 to pay off and only had this car a year and I am going to have to give it back and keep paying for it, for 5* years. I feel so upset and cannot believe Ford is doing this to people and getting away with it. This ruined my life and I will probably lose my job now cause I have no means of transportation. This needs to be recalled! It's not right

- Tamaqua, PA, USA

Component failure: Engine -- Catastrophic engine failure due to coolant leakage onto the engine block. EcoBoost engine. Dealership confirmation that car engine will need full replacement - car essentially scrap metal without new engine. At the time of this failure car had approximately 40,000 miles odometer read total on it and maintenance was up to date. Personal safety - I was driving the car on a Freeway with other vehicles at approximately 65 mph and the entire car began to shudder and I lost the ability to accelerate. The road was on an uphill trajectory and I was in the middle lane - I had to navigate my vehicle to the right hand lane and off the freeway at the next exit - I and others were at high risk of a collision due to the severity and sudden failure of the engine while on a busy road. Dealer confirmation: Dealership had specific codes on the diagnostics decribing this issue. Repair offered was replacement of the long block with a Ford engine that had been modified to fix the coolant leakage problem. Essentially Ford was offering a new TYPE of engine instead of a fix with the same model the car originally had. Dealership was aware of this engine coolant issue with Ecoboost, they revealed Ford was aware of the issue but never issued a recall. We were given the customer complaint line and were told FORD has been offering SOME people new engines at no cost. We were rejected by Ford customer line and told to file a complaint here. Essentially described by dealership repair as need to replace the long block (entire engine) to fix the problem or replace the short block only to expect it to happen again. The cost to replace the long block was quoted at $9500. Inspection and repair worksheets available from owner. Warning signs: NONE. Check engine light came on approximately 30 seconds AFTER symptoms on freeway began.

- Auburn, CA, USA

My car has about 120k miles on it. The issue is that the coolant leakes into the cylinders. Tried replacing cylinders but problem came back. Dealership says the engine needs repair. The safety issue I had was I was driving on the hwy at about 60. The car suddenly went from 60 to 30. If a car had been behind me I would have been hurt. The manufacturer ford will not pay. I have seen many of this exact same issues on your website. This IS a safety issue. What can you do?

- Wausau, WI, USA

My ecoboost Ford Engine in my 2016 Fusion leaks coolant into my 1, 3 and 4 cylinders, over heated, smoke coming out of exhaust, using coolant. I took it to the Ford dealer to have it checked out when all of a sudden while driving the red temp light went off and my check engine light started blinking with a warning light saying critical temperature and I had to pull off side of highway, they said it needs a new motor, he also said it was common for this size engine to have issues, Ford had been dealing with that it was a design flaw............yet they won't fix it free or recall it. they want $8500 for a new engine, which I can't afford, so a car I own and owe on just sits undriveable. He said they offered an extended warranty to replace the short block on 2017 -2019 but mine is 2016 so no extra help was given to people who owned that year, even though its the same engine, flaws and all.

- Logansport, IN, USA

The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the engine coolant over temperature warning light illuminated. The contact stopped the vehicle and checked the coolant level. The contact stated that the coolant level was sufficient. The contact proceeded to drive the vehicle to the intended destination. The contact stated that when the speed increased above 20 MPH, the vehicle jerked violently. The engine overheated and then seized. The vehicle was towed to an independent mechanic where it was diagnosed with engine failure due to coolant intrusion into the cylinders. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The dealer was made aware of the failure. The manufacturer was made aware of the failure. The failure mileage was approximately 110,500.

- Columbia, MD, USA

Coolant leaking into engine, causing low engine coolant levels, and affecting performance. Ongoing problem for a while, officially diagnosed on 6/21/2024.

- Sheridan, OR, USA

I started the vehicle and smelled ash. As I drove away from home at very low speed in my neighborhood, I started to notice white smoke which gradually increased. I immediately parked the car. There was no signs of leaks under the vehicle (but it has extensive underbody covesr). There was moisture and fluid droplets coming from the exhaust pipes. I started the vehicle remotely to view it from the rear and witnessed white smoke coming out of the exhaust pipes, then immediately shut it off. I had it towed to my mechanic who checked the vehicle and noted no issues with the coolant combustion or engine pressure. I had it towed to another shop which replaced the turbo last year, and they checked it for turbo issues. They noted that the engine is dumping coolant into the exhaust system, and that this is an issue know to Ford.

- Joint Base Mdl, NJ, USA

Started with a check engine code misfire in cylinder 3. Took it to a shop for them to say I needed a new spark plug and coil. Replaced the parts, and still had the code. Kept driving the car and then started having rough idling, white exhaust smoke, and stalling. Upon further research noticed I was missing coolant but the mechanic couldn-??t find the leak. Continued driving the car, experiencing trouble accelerating, stalling, and white exhaust smoke. Replaced fuel injectors. Up until one day I went to start the vehicle and it would crank but not turn over. Had it towed to a mechanic who said they couldn-??t explain why I had no spark. Then to another mechanic who said I have coolant leaking into my cylinder 3 that will require engine replacement. This is a known issue with fords with the same engine. Addressed ford and they said there was nothing they could do without a recall.

- Lakeland, FL, USA

Coolant intrusion into cylinder(s): My vehicle suddenly overheated while I was traveling on a highway that had stretches of ongoing construction and no shoulder. While attempting to reach a portion of the highway with a shoulder, my car went into "limp" mode. I had to shut the vehicle off and wait for it to cool. After about an hour I was able to have someone bring me coolant and I was able to restart my vehicle and get to a safe location. My car continues to overheat whenever I try to accelerate on a highway, leaving me in a position where I am trying to pull my car to the shoulder without causing an accident. There is white smoke coming from my exhaust, my check engine light comes on, and I am losing coolant, although no leaks can be found. My car has ALL symptoms listed under Ford's Technical Service Bulletin 20-2100 issued 01 April 2020 titled "TECHNICAL SERVICE BULLETIN 1.5L EcoBoost - Low Coolant, White Exhaust Smoke And/Or Illuminated MIL - Built On Or Before 10-Jun-2019". This intrusion can cause my vehicle to catch on fire! I have had my vehicle evaluated and scanned and am now having to spend over $1,500 to replace the water pump in hopes it alleviates the overheating. Ford is expressly aware of this issue, and I have found that there have been multiple class-action suits filed against Ford for this exact issue.

- Glen Burnie, MD, USA

This car has a coolant leak failure where coolant has leaked into the engine and showing no signs of a visible leak. This is exactly the same failure mode as all of the ford fusion recalls with the same engine but for whatever reason this VIN was not included in the recall. I have filed a complaint with Ford #02160862 but they state there is nothing they can do. I have reviewed my options with the dealership and they said that Ford doesn-??t even offer remanufactured engines for this vehicle because they all experience the same coolant issue. This statement alone shows that Ford is aware of the issue but not doing anything about it. Replacement with a brand new engine quoted at $11k is the only path forward.

- Hollis, NH, USA

As me and my daughter had been out all day on the way home the coolant light comes on it-??s overheating so we stop and waited bout 15 minutes started home again same thing happened then the car started misfiring checked coolant it was low put some in then in a couple days coolant was gone again took to shop to look for leak was informed motor was going bad never had issues out car till coolant started leaking looked it up that was one of ford biggest problems with the ford fusion but no recall has been stated for this problem so I would b careful of the coolant systems

- Altavista, VA, USA

The contact owns a 2016 Ford Fusion. The contact stated that the vehicle was taken to the dealer for several recall repairs. The contact stated that the recall repairs were performed; however, while driving at approximately 40 MPH, the check engine warning light illuminated, and the contact observed that the coolant was empty. The contact refilled the coolant, however, the failure recurred, and the contact refilled the coolant several times. The contact stated that no leak was found, however, the motor oil was an orange color. The contact stated that while driving the vehicle misfired and white smoke came out from the exhaust. The dealer was contacted. The vehicle was not repaired. The contact discovered the Technical Service Bulletin 19-2139; however, it was unknown if the contact's VIN was included. The manufacturer was made aware of the failure. The failure mileage was approximately 133,000.

- Florence, AL, USA

Head gasket and block cracked and caused coolant to leak into cylinder and caused misfiring and over heating and check engine light with smoke coming out of tailpipes

- Centennial, CO, USA

The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic and a tune-up was performed. The failure reoccurred, and the vehicle was taken back to the independent mechanic where it was diagnosed with a coolant leak. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and the contact was advised to report the failure to the NHTSA Hotline. The failure mileage was approximately 85,000.

- Lincoln, NE, USA

The engine failed completely needing full replacement @ 110,270 miles. Technical Service Bulletin 22-2322, super ceding TSB 22-2134 (attached file ford gave me) Coolant leak into cylinder 2 due to engine defect. I was getting on the highway when the car suddenly started overheating, the warning light did come on. This was roughly around [XXX], I do not recall the exact date. Then suddenly everything went back to normal. Engine temp was perfect within a second. When I got home, I checked the coolant, and it was very low. So, I replaced the coolant. The next time I started the car it barely started, and White smoke poured out the exhaust. I then parked it in the garage, and it sat. After researching what the issue was. I knew I couldn't afford a $10,000 bill. Recently I had to take a loan and brought the car in to be inspected and repaired. The engine, Turbo, Tires, and some miscellaneous work was all done at the time. It was towed in on [XXX]. The engine was serviced by Van Horn Ford of Sheboygan. Service advisor knew what the issue was before I even brought the car in just from the description. Even said he's seen a few with the same exact issue over the years. I didn't bring the car in initially because I bought it used so it didn't have a warranty and I knew I could not afford to replace it at the time. It costed about $10,074.44 plus some miscellaneous parts. I will have attached the Parts and service list. Not only did the defect ruin the engine, but also the turbo, both recommended to be replaced. This problem could have started the engine on fire if I did not catch it and stop driving the vehicle. I did end up going through all repairs by taking a loan out of my 401K to repair it. I attached both the service / parts list. as well as the Service bulletin the Ford service advisor gave me. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Sheboygan, WI, USA

My 2016 Ford Fusion with 90,000 miles has a coolant intrusion problem. This has caused my car to shake, smell, run terribly, hesitate while driving in traffic, almost losing power and now not starting. The first time I had trouble starting my car I took it to the Ford dealer that has always worked on my cars and was told I have a coolant intrusion issue. They said coolant leaked into a cylinder due to a design issue and there is no recall at this time. My service engine light would go on and off. When we called the dealer about the light going on and then not coming back on for weeks at a time they said when the light goes back on and stays on to call them and they would have a look. This started about 6 months ago. The light would only light up a couple of times and go back out. My car has not started since the beginning of April 2024. The dealer has quoted us $10,000 to fix this problem of a faulty designed motor.

- Gowanda, NY, USA

Was driving and vehicle started to shake and lose speed. Check engine light came on. Checked and said misfire in cylinder 3. Took to mechanic and said coolant leaked into engine, plugs were corroded and heads cracked. Total engine replacement needed. Ford does not have recall for this year or model even though it's a widely known issue. I still have a loan on this car that I now can't drive as I don't have an extra $5000 to pay for an engine and my extended warranty won't cover it.

- Thomasville, NC, USA

Antifreeze is leaking into the engine and now the engine needs replaced. Ford is aware of faulty 2.0 turbo engines but has not recalled it. I bought an extended warranty and they won't cover it. I have been a Ford guy my whole life but that will change because Ford knows about the issue but won't do anything about it.

- Columbus, NE, USA

The engine cooling failed inside the block on cylinder #2. The cooling system is not operable and resulted in blue smoke under acceleration. The car is no longer under warranty and only has 65K miles on it and is otherwise in good working order. I am told the whole engine needs to be replaced.

- Lansing , MI, USA