Electrical complaints by model year
Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
What owners report
The contact owns a 2020 Ford Fusion. The contact received notification of NHTSA Campaign Number: 23V440000 (Electrical System) however, the part to do the recall repair was not yet available. The contact stated that while operating the A/C, the fan motor started to increase in speed and the battery became hot. The contact stated that she unplugged the battery to allow for the battery to cool down before reconnecting the battery. The vehicle was taken to an undisclosed dealer however, the failure could not be duplicated. The contact was informed that parts were not yet available for the recall repair. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The failure mileage was approximately 30,000. VIN tool confirms parts not available.
The contact owns a 2020 Ford Fusion. The contact received notification of NHTSA Campaign Number: 23V440000 (Electrical System) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that while driving at undisclosed speeds, after the electrical charge had diminished, the vehicle lost automotive and electrical power instead of switching over to fuel. The contact was informed not to charge the vehicle making the vehicle undriveable. The manufacturer was made aware of the failure. The approximate failure mileage was 62,000. VIN tool confirms parts not available.
The contact owns a 2019 Ford Fusion Energi. The contact received notification of NHTSA Campaign Number: 23V440000 (Electrical System); however, the part to do the recall repair was not yet available. The contact stated while driving at an undisclosed speed, the plug-in battery failed. The contact stated that he was able to continue driving and pulled into his friend's garage. The contact stated that he turned off and restarted the vehicle, and the check engine warning light and the power train warning light were illuminated. The vehicle was taken to the dealer, where the battery energy control module was replaced; however, the failure reoccurred a month and nine days later. The contact stated while that starting the vehicle, the check engine warning light and the power train warning light were illuminated. …
The contact owns a 2019 Ford Fusion. The contact received notification of NHTSA Campaign Number: 23V440000 (Electrical System) however, the part to do the recall repair was not yet available. The local dealer was made aware of the issue and confirmed that parts were not yet available. Recently while driving at 25 MPH, the contact stated that an abnormal, popping sound emitted from the vehicle. An unknown "red triangle" and an unknown warning message also appeared on the instrument panel. The cabin began to fill with heavy grayish smoke as the contact and her husband immediately exited the vehicle. The authorities were called to the scene and disconnected all electrical wires from the vehicle. No fire was reported. A police report was filed. The contact's husband, who recently had surgery on his left rotator cuff, fell on his left shoulder upon exiting the vehicle. …
The contact owns a 2018 Ford Fusion Energi. The contact stated that the hold voltage battery had decreased to 13-15 miles on a full charge when previously averaging 22-23 miles. There were no warning lights illuminated. The contact stated that the failure was related to Customer Satisfaction Program: 24N19. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and transferred the contact to the NHTSA Hotline. The failure mileage was approximately 80,000.
Ford Fusion energi battery failure. Dealership wouldn't inspect the battery and kept replacing the battery control module. The replacement part kept failing under warranty and then the dealership quoted me $20,000 for the hybrid battery. They have replaced the BCM twice and error code P0dc9 keeps appearing. The EV range drops to zero randomly or gains range while parked and not plugged in. Dealership doesn't know what's happening even after paying money for diagnostics.
The contact owns a 2017 Ford Fusion Energi. The contact stated that after her son had parked and turned off the vehicle and upon returning to the vehicle, the vehicle failed to restart. The vehicle was towed to the dealer, where it was diagnosed with battery failure. The vehicle was not repaired due to the cost and remained with the dealer. The manufacturer was notified of the failure and an estimate of the battery cost was available; however, the contact was unaware when the battery would be in stock. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 160,000.
Car was sitting in my driveway and the back lithium ion battery in trunk had a short and started on fire while car was off and not plugged in. Burnt through trunk and into back seat and both speakers are gone. Car has heavy smoke damage and all windows are bad. Found battery harness with completely melted where it plugs into battery.
NHTSA investigations
Pedestrian alert sounds
NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles.
Frequently asked questions
Which Ford Fusion Energi years have electrical problems?
By NHTSA complaints, the 2019 (102), 2020 (38), 2015 (10), 2013 (9) and 2016 (8) model years. Electrical complaints make up 84% of all complaints for the 2019.
Is there a recall for Ford Fusion Energi electrical problems?
No. NHTSA lists no electrical system recall for any Ford Fusion Energi model year. A widespread problem may still be covered by an extended warranty or a manufacturer service bulletin, so ask a dealer.
At what mileage do Ford Fusion Energi electrical problems start?
Across all years, half of the complaints with a recorded mileage happened before about 44,000 miles; 70% happened before 50,000 miles.
What part fails most often?
Owners most often name the 12v/24v/48v battery (4 mentions), followed by the propulsion system › traction battery › management system/energy control module (bms/becm) (2).
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.