Throttle body failure
the car going dead on the highway with no warning and entering a fail-safe mode
Check engine light: On
This is the most frequent engine problem for this generation and a genuinely safety-relevant one: throttle body failure, with owners describing the car going "dead on the highway with no warning" and entering a fail-safe mode. It's tied to a Ford service bulletin (13NO3) rather than a formal safety recall, but the symptom is serious enough that it shouldn't be treated as routine wear. Documented cost range of $150 to $455. Throttle body faults commonly trigger a check-engine light.
$150 – $45522,000–109,000 mi
tied to Ford Service Bulletin 13NO3, not a formal safety recall — but the "car went dead on the highway" symptom is serious enough that it should not be treated as routine wear.
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Motor/engine mount failures
vibration or a grinding noise during acceleration
Check engine light: Off
Engine mount failure shows up with a documented cost range of $400 to $1,600. Reported between 61,000 and 134,000 miles. This is a mechanical fault, so it doesn't trigger a check-engine light.
$400 – $1,60061,000–134,000 mi
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Valve cover gasket leaks
an oil leak
Check engine light: Off
Valve cover gasket leaks show up with a documented cost range of $150 to $725. Reported between 39,200 and 66,000 miles. This is a mechanical oil-leak fault, not a sensor or emissions issue, so it doesn't typically trigger a check-engine light.
$150 – $72539,200–66,000 mi
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Coolant system issues — some very early-life
a fluid swishing sound from trapped air in the cooling system, or low coolant levels
Check engine light: Off
Coolant system issues — air trapped in the system causing an audible swishing sound, along with low coolant levels — appeared notably early in some vehicles' lives, as early as 5,000 miles. We've widened one documented $350 case into a $280-$385 range; other cases documented were warranty-covered. This is a mechanical coolant fault, so it doesn't typically trigger a check-engine light unless it progresses to overheating.
$280 – $3855,000–21,700 mi
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Ignition/starting issues — very early-life
the engine simply not starting, intermittently
Check engine light: Off
The earliest-occurring issue in our entire sample for this vehicle: intermittent no-start conditions reported as early as 1,000 miles, continuing through 11,000 miles — suggesting a manufacturing or setup defect on at least some vehicles rather than ordinary wear. A flat no-start condition typically doesn't set a check-engine light on its own, since the engine control system may not log a fault code before the engine actually runs.
1,000–11,000 mi
notably early mileage range — the earliest-occurring problem reported for this vehicle. No repair costs were reported.
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Belt/pulley component noise
whining, grinding, or squeaking noise
Check engine light: Off
Belt and pulley component issues cause whining, grinding, or squeaking noise, with a documented cost range of $320 to $800 given how wide the reported mileage range is (16,000 to 238,000 miles). This is a mechanical noise fault, not an emissions issue, so it doesn't typically trigger a check-engine light.
$320 – $80016,000–238,000 mi
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Emissions system parts (EGR valve, purge valve, EVAP components)
a check engine light from an emissions-related component
Check engine light: On
Emissions-system components — EGR valve, purge valve, and EVAP parts — show a documented cost range of $500 to $576. Reported between 25,000 and 103,000 miles. Emissions component faults directly set a check-engine light by definition.
$500 – $57625,000–103,000 mi
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Oxygen sensor failures
a check engine light
Check engine light: On
Oxygen sensor failure is a typical high-mileage wear item for this generation, with a documented cost range of $550 to $260. Reported between 80,000 and 102,000 miles. Oxygen sensor faults directly set a check-engine light by definition.
$550 – $75580,000–102,000 mi
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Harsh or delayed shifting of automatic transmission
Automatic transmission shifts harshly or with a delay
Check engine light: On
Automatic transmission shifts harshly or with a delay. This is among the more frequently reported issues on this generation, with 1,180 owner reports on file.
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Squeaks and creaks over bumps and while turning
Squeaks and creaks over bumps and while turning
Check engine light: Off
Squeaks and creaks over bumps and while turning. This is among the more frequently reported issues on this generation, with 479 owner reports on file.
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Swollen lug nuts
Lug nuts swell, complicating wheel service
Check engine light: Off
Lug nuts swell, complicating wheel service. This is among the more frequently reported issues on this generation, with 294 owner reports on file.
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Brake issues — spongy pedal, repeated caliper, pad, and rotor replacement
Spongy brake pedal with repeated caliper, pad, and rotor replacement
Check engine light: Off
Spongy brake pedal with repeated caliper, pad, and rotor replacement. This is among the more frequently reported issues on this generation, with 243 owner reports on file.
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Transmission oil leaks from left side half shaft area
Transmission oil leaks from the left-side half shaft area
Check engine light: Off
Transmission oil leaks from the left-side half shaft area. This is among the more frequently reported issues on this generation, with 205 owner reports on file.
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Sunroof not closing properly, gaps and water intrusion
Sunroof fails to close properly, leaving gaps and letting water in
Check engine light: Off
Sunroof fails to close properly, leaving gaps and letting water in. This is among the more frequently reported issues on this generation, with 176 owner reports on file.
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CD player not working
CD player stops working
Check engine light: Off
CD player stops working. This is among the more frequently reported issues on this generation, with 147 owner reports on file.
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Key will not come out of ignition
Key gets stuck and will not come out of the ignition
Check engine light: Off
Key gets stuck and will not come out of the ignition. This is among the more frequently reported issues on this generation, with 108 owner reports on file.
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Cold start — cranks but no start below 30°F
Engine cranks but won't start in temperatures below 30°F
Check engine light: Off
Engine cranks but won't start in temperatures below 30°F. This is among the more frequently reported issues on this generation, with 81 owner reports on file.
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Fusion Sport AWD power transfer unit leaking fluid, burning smell
Fusion Sport AWD trim: power transfer unit (PTU) leaks fluid, with a burning smell and performance issues
Check engine light: Off
Fusion Sport AWD trim: power transfer unit (PTU) leaks fluid, with a burning smell and performance issues. This is among the more frequently reported issues on this generation, with 75 owner reports on file.
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Trunk will not latch closed
Trunk fails to latch closed
Check engine light: Off
Trunk fails to latch closed. This is among the more frequently reported issues on this generation, with 54 owner reports on file.
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Power steering fluid leakage
Power steering fluid leaks
Check engine light: Off
Power steering fluid leaks. This is among the more frequently reported issues on this generation, with 42 owner reports on file.
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Shifting concerns for six-speed automatic transmission
Shifting concerns specific to the six-speed automatic transmission
Check engine light: On
Shifting concerns specific to the six-speed automatic transmission. This is among the more frequently reported issues on this generation, with 41 owner reports on file.
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The most notable issue not covered by a recall is throttle body failure. It is the most frequently reported engine problem on this generation, with owners describing the car going "dead on the highway with no warning" and entering a fail-safe mode. It's tied to a Ford service bulletin rather than a formal recall, but the symptom is serious enough that it should not be treated as routine wear. Separately, this generation's very high complaint volume is driven substantially by four confirmed recalls — see the recall notice below rather than the list above for those.