The flexplate in my 2020 Ford Fusion SE (1.5L EcoBoost engine) failed at just over 53,000 miles. The car began making loud knocking and rattling noises while driving, and it vibrated heavily at idle and during acceleration. This posed a serious safety concern, as we feared the car could stall or break down while on the road with our toddler in the backseat. We took it to an independent, certified repair shop where they diagnosed a broken transmission flexplate, which required immediate replacement. The repair cost nearly $3,000, and the shop confirmed it was not caused by driver error or normal wear-and-tear. The failure was premature and mechanical in nature. The mechanic informed us that this specific engine and flexplate design have been recalled before in other Ford models using the same 1.5L EcoBoost engine and parts. They suggested we contact Ford, as this appeared to be a known defect that should be covered under goodwill or extended warranty. We followed their advice and reached out to Ford directly, but Ford refused to offer any assistance -?" even though they are aware of these ongoing flexplate failures across similar vehicles. After researching, I discovered Ford has had multiple flexplate and powertrain-related recalls in other 1.5L and 1.6L EcoBoost engines in previous model years. I also found many online complaints from other Ford owners experiencing the same flexplate failures, often at similar mileage. Yet, this issue has not been acknowledged or recalled for the 2020 Ford Fusion SE. This is clearly a design or manufacturing flaw that should be investigated by the NHTSA. Flexplate failure puts lives at risk and results in major repair bills for consumers. Please investigate this ongoing issue before someone is seriously hurt.

- Cedar Park, TX, USA

The contact owns a 2020 Ford Fusion. The contact stated that while driving at various speeds or while the vehicle was idling, there was an abnormal clunking sound coming from the vehicle. There were no warning lights illuminated. The vehicle was taken to the local dealer where it was diagnosed and determined that the flex plate had fractured. The vehicle was repaired; however, the failure recurred. The manufacturer was not contacted. The failure mileage was approximately 25,000.

- Kingman, AZ, USA

I purchased a used 2020 Ford Fusion from Carmax n 2023 with about 56,800 miles. A week later was involved in a nor side impact accident on the back end driver side, insurance paid for a dinted door and there was no other issues with the vehicle according to SONS ford. In 2024 I was on the highway (going about 80 mph) when my engine light came on, no more than 3 minutes later all the lights in my car flickered and i lost power to my entire car almost causing me my life, roadside assistance and a mechanic who had thankfully pulled over explained that my alternator completely shredded my belt. I paid for both my alternator and belt to be replaced But most recently (2025) I continued to whirring and knocking noises for 3 days (no warning lights), I took it to firestone who stated I needed a motor repair so I got it towed to the dealership. A Ford certified mechanic stated my Flex Plate was cracked and it begin breaking off and how I needed a new starter as well leaving the car inoperable. They confirmed this was very uncommon due to the car age and the miles on it (80,000 mi) I-??ve also reviewed the complaints on NHTSA and it looks like a lot of 2020 ford fusions are having these issues but yet no recall.

- Phenix City, AL, USA

My car is at 47,000 miles and i started To hear a loud noise. Turns out ford says it-??s the Flywheel, transmission pump, and torque converter per ford technician who completed my inspection. No warning lights came on nor was there any alerts the ford app. My 2020 Ford Fusion with approximately 48,000 miles experienced a cracked flexplate. This caused severe engine vibration, knocking sounds, and ultimately loss of power while driving. A cracked flexplate can lead to sudden engine stalling or failure to accelerate, especially at highway speeds or during intersections. This puts the driver and passengers at serious risk of a crash due to unexpected loss of power or control. This issue happened without warning and is a known problem in vehicles with the 2.0L EcoBoost engine and 6F35 transmission. Ford is aware of the issue (Customer Satisfaction Program 22N12), but my VIN was not included, even though the symptoms and components match the defect. I am reporting this because it jeopardized my safety and others on the road, and I believe more vehicles should be covered under the existing CSP or a recall.

- Suwannee , GA, USA

The contact owns a 2020 Ford Fusion. The contact stated that while driving 35 MPH and attempting to pull into a store parking lot, there was an abnormal whining sound coming from the vehicle. The contact stated that when the gear shifter was shifted to park or neutral, the sound ceased. The contact stated that the sound returned while shifted into drive or reverse. There were no warning lights illuminated. The vehicle was taken to the local dealer in where it was diagnosed and determined that the transmission needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline. The failure mileage was approximately 65,000.

- Ormond Beach, FL, USA

The contact owns a 2020 Ford Fusion. The contact stated that while driving at various speeds, the vehicle was driving rough. The contact stated that the vehicle hesitated while accelerating with a whining sound coming from the transmission. The cause of the failure was not yet determined. The local mechanic was notified of the failure and informed the contact that the transmission was faulty and needed to be replaced. The manufacturer was contacted and informed of the failure; however, no assistance was provided. The local dealer was not contacted. The failure mileage was 100,000.

- Palmer, TN, USA

The contact owns a 2020 Ford Fusion. The contact stated that upon starting the vehicle, there was an abnormal rattling sound coming from the engine compartment. No warning lights were illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the crankshaft flex plate. The vehicle was not repaired. After investigating the failure, the contact related the failure to Customer Satisfaction Program: 22N12. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 71,000.

- Dallas, GA, USA

The contact owns a 2020 Ford Fusion. The contact stated that after starting the vehicle there was an abnormally loud knocking sound coming from the engine compartment. The vehicle was taken to the local dealer who diagnosed that the flex plate was cracked and needed to be replaced along with the torque converter, the transmission fluid pump, and seals. The vehicle was repaired. The manufacturer was notified of the failure and informed the contact that the vehicle was no longer eligible for a Customer Satisfaction Campaign related to the failure. The failure mileage was 122,000.

- Coudersport, PA, USA

The contact owns a 2020 Ford Fusion. The contact stated that while reversing from the residence, the vehicle suddenly stopped and shifted into park. The contact shifted to reverse, but the gear shifter independently shifted back to park. The contact stated that the vehicle failed to shift to the intended gear. The transmission shifter and the see the owner-??s manual messages were displayed. There was a WRENCH symbol displayed. The contact stated that the failure was related to NHTSA Campaign Number: 22V413000 (Power Train); however, the VIN was not included. The contact called the local dealer, who confirmed that there were no recalls on the VIN. The vehicle was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline, but no additional assistance was provided. The failure mileage was approximately 79,127.

- La Fayette, GA, USA

Component or system that failed: Flex plate, engine electrical system, and alternator (possible related failures). The issue has been diagnosed by a licensed mechanic and is available for inspection upon request. Incident Description: On April 15, 2025, while driving my 2020 Ford Fusion SE 1.5L Turbo, the vehicle suddenly experienced a total power failure. The check engine light began flashing, and the battery light blinked rapidly. Within seconds, the engine shut down completely while I was mid-drive in traffic, leaving me stuck and unable to move for over 20 seconds. This was a terrifying and dangerous situation that nearly put my life at risk. I was eventually able to restart the vehicle, but it began shaking and rumbling violently -?" worse than ever before. This issue was never present before my car was involved in two separate collisions, where both other drivers were found 100% at fault. The vehicle was repaired at Fix Auto Santee (a USAA-assigned body shop), but they failed to inspect internal components. A licensed mechanic at J&L Auto Care later confirmed a broken flex plate and advised it was unsafe to drive. This problem has not been addressed or fixed by the responsible insurers (USAA and AAA) or the body shop. It has progressively worsened and now created a life-threatening situation. Warning lamps or symptoms before failure: A rattling and vibrating noise began immediately after I picked up the car from the body shop in March 2025. No lights were initially present. The electrical and engine lights only appeared on April 15 when the engine shut down mid-drive. Inspected by: -??Independent service center (J&L Auto Care, diagnosed flex plate failure) -??USAA and AAA were informed but refused to cover or further inspect the damage -??Fix Auto Santee heard the issue but refused to inspect, citing body-only service Problem available for inspection: Yes -?" vehicle is currently undrivable and available for full inspection.

- Lakeside, CA, USA

My flex plate is cracked making the car unsafe to drive there are recalls on other years and vehicles with the same engine and power train and same flex plate as mine but my vin# says no recall I find it interesting that they can justify not replacing a known faulty part. The campaign 22N12 covers other 2020 ford fusions

- Kings Mountain, KY, USA

The contact owns a 2020 Ford Fusion. The contact stated that while driving at approximately 40 MPH, there was an abnormal rattling sound coming from the engine compartment. The contact stated that the sound was more evident while the vehicle was idling. The vehicle was taken to an independent mechanic and was diagnosed with a fractured flex plate. The contact was informed that the flex plate needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 63,000.

- Roanoke, TX, USA

My vehicle was in service with my dealer for several months 3 separate occasions for powertrain issues which werent resolved and now the alignment in my steering wheel is really off. My spouse and I believe the PCM is messed up but have had no progress with our dealership and suspect them of committing consumer fraud and selling us a lemon. The vehicle in question is around 70,000 and started messing up at 60,000.

- Beaumont, TX, USA

Began to hear loud rattling noise under hood. Brought to Ford dealer who determined the cause is a failed Flex Plate. Car is operable but was warned this could result in catastrophic failure of the transmission. Vehicle has approximately 62,000 miles, just 2,000 miles out of warranty. Ford Customer Satisfaction Program 22N12 address the issue with an extended warranty for certain model variants (Vehicles Equipped with a 2.0L EcoBoost Engine and 6F35 Transmission). My vehicle has suffered the same failure but has a 1.5L engine so has been excluded.

- Lebanon, CT, USA

The steering cable is connected to the transmission hub, and the fitting that connects the two has a gasket that wears away and falls out. This is a recall with vehicles that are made from one of the two plants that assemble fusions, however my vehicle is not covered under the recall even though it is the very same issue as the recall from the other plant. it makes no sense, why is one assembly plant offering a recall for this issue while the other does not? For the same issue of the steering cable coming off the transmission, and not allowing the vehicle to go into gear. I have had to fix this car on the side of the highway before, it will not go into gear on the road. This is not safe at all. You cannot have vehicles just not going into gear while your driving down the highway, or road, street, etc.

- Albion, MI, USA

Hard shifting when accelerating/decerating, jerking of the car due to transmission issues (80k miles), ABS/Braking issues due to engine components not being in sync, etc

- Wayne, MI, USA

Car shifts into 1st gear when traveling at higher speeds (45+mph), causing a significant jerk and almost causing a rear end collision to myself. Car also loses power and jerks significantly hardwhen shifting to reverse and drive from Park. Afraid to travel over 45mph due to the downshifting.

- Plattsburgh, NY, USA

The contact owns a 2020 Ford Fusion. The contact stated that the fuel door would randomly disconnect from the vehicle. While idling at a stop light, the vehicle shut off. The contact stated that while restarting the vehicle the vehicle jerked and hesitated while shifting gear before accelerating. The vehicle was taken to the dealer who was unable to determine the cause of the failure because there was no warning light illuminated. The fuel door had been replaced; however, the vehicle still experienced the failure with the START/STOP function. The contact stated that the failure became a persistent failure. The contact stated that approximately 6 to 8 months after the first failure, while driving approximately 35-45 MPH, the vehicle stalled. The contact used the App to restart the vehicle. The check engine warning light was illuminated. The vehicle was returned to the dealer however, the cause of the failure could not be determined. The dealer rebuilt the transmission, clutch, and axle; however, the failure persisted after the repairs. The vehicle was returned to the dealer who was unable to determine the cause of the failure. The vehicle had been taken to the dealer 22 times. The manufacturer was not made aware of the failure. The approximate failure mileage was 25,000.

- Burlington, NC, USA

On Saturday, October 5th, 2024, at around 5AM I was sitting in the Starbucks parking lot outside of the Detroit Metro (DTW) airport when this issue began. I had just started my car and could feel it was sluggish and was making a significant amount of noise, which was present in park and neutral, but not so much while in gear, unless I was stopped at a stop sign or stationary. After getting home, and each day after when I started the vehicle to go to work, I could hear that the noise was progressively getting worse. So, I determined that it was not a fluke and took my car into a Ford dealership to have the oil changed and a full inspection done. They explained to me that the water pump had failed and was leaking, very slowly, but externally through the "weep hole". They were going to charge me $1,300 to repair. So, I called a local shop that I know is reputable and they confirmed the water pump leak but determined that the noise I was hearing was not the water pump, but actually a cracked flexplate. The noise originated near the starter, and the shop ran a camera through the inspection hole confirming this. After I found that the flexplate was cracked, I did not continue to drive it, but scheduled a repair to begin on Thursday, October 24th at the reputable shop I mentioned above. To complete the repair, they needed to drop the cradle, remove the transmission and support the engine. This in total cost me $1,729.60. The flexplate has not been inspected by the mfg., police, insurance, etc., as there was no need. I did not have an extended warranty and though my car is only 4 years old, it was beyond the warranty in miles. No lights appeared on the dash, and there were no error codes present. The flexplate cracking could have resulted in catastrophic failure of the engine or transmission, and I could have very well lost control of my vehicle. If I was driving on the highway during a failure, my safety as well as others would have been put in serious danger.

- Durand, MI, USA

On [XXX] I backed my 2020 Ford Fusion out of my driveway. I stopped and tried to shift from reverse to drive and the transmission locked up in Park, the engine died and the parking brake was engaged. I was sitting across the street with no way to move the car. I had the car towed to a Ford dealer and they replaced the transmission cable bushing and cover. These parts are the same as those used in Fords recall 22S43. Ford continued to use inferior parts on cars built after the dates mentioned in the recall. This is a safety issue as it could happen at any time. Thanks [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Naperville, IL, USA