2010 Ford Fusion Hybrid Brake Problems

Which parts fail

• Antilock/traction control/electronic limited slip › Wheel speed sensor/tone ring
  1
• Antilock/traction control/electronic limited slip › ABS warning light
  1
• Foundation components › Disc › Caliper
  1
• Antilock › ABS warning light
  1

Components named in complaints (service brakes, ABS, rotors and pads, parking brake).

Mileage when the problem started

• Under 25k
  34%
• 25k–50k
  78%
• 50k–75k
  1214%
• 75k–100k
  1214%
• 100k–150k
  3643%
• 150k+
  1316%

Owner reports

Selected complaints filed with NHTSA by 2010 Ford Fusion Hybrid owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owns a 2010 Ford Fusion Hybrid. The contact stated while driving 7-10 MPH and depressing the brake pedal, the brake pedal felt stiff. The contact stated that while depressing the brake pedal harder, the vehicle hesitated to respond, causing the braking distance to be extended. The ABS warming light and several other unknown warning lights were illuminated. The contact resumed driving; however, the failure worsened, and the vehicle failed to stop. The contact engaged the electric parking brake, and the vehicle stopped. The vehicle was towed to the dealer, where it was diagnosed that the ABS module, Part Number: BE5Z2C219H, had failed and needed to be replaced; however, the dealer informed the contact that the part had been discontinued. The vehicle was not repaired. …

The contact owns a 2010 Ford Fusion. The contact stated that while driving at 20 MPH, the brake pedal depressed to the floorboard as extra travel time was needed to stop the vehicle. The check brakes warning message appeared on the instrument panel during the failure. As the contact attempted to pull over to the side road, extra steering effort was needed to steer the vehicle. Due to the failure, the vehicle was towed to a dealer where they informed him that the ABS module needed to be replaced; however, the part was on backorder. The manufacturer was notified of the failure and confirmed that the parts were on backorder. The contact was also notified that there were no recalls on the vehicle and was then referred to the NHTSA for assistance. The vehicle had yet to be repaired and remained in the possession of the dealer. The failure mileage was approximately 133,000.

The contact owns a 2010 Ford Fusion Hybrid. The contact stated while slowing for a traffic signal at approximately 20 MPH, the ABS and several other brake warning lights illuminated. The contact depressed the brake pedal however, the vehicle was not slowing down as needed. The contact stated that the brake pedal was depressed down to the floorboard. The contact stopped the vehicle by engaging the parking brake. The contact had the vehicle towed to a non-manufacturer dealer who diagnosed the vehicle and determined that the ABS Hydraulic Control Unit needed to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure. The contact researched online and related the failure to NHTSA Campaign Number: 19V904000 (Service Brakes Hydraulic) however, the VIN was not included. The failure mileage was approximately 120,000.

The contact owns a 2010 Ford Fusion Hybrid. The contact stated that while driving 15 MPH and depressing the brake pedal, the brake pedal went to the floorboard. The contact stated that the brake system, ABS, and traction control warning lights were illuminated. Additionally, the message "Brake System Failure" was displayed. The contact drove with caution to the residence, and then had the vehicle towed to an independent mechanic to be diagnosed. The contact was informed that further diagnostic testing was needed to determine the cause of the failure. The vehicle was not repaired. The contact referenced NHTSA Campaign Number: 19V904000 (SERVICE BRAKES, HYDRAULIC) as a possible cause for the failure. The manufacturer was notified of the failure. The approximate failure mileage was 162,000.

The contact owns a 2010 Ford Fusion. The contact stated while driving 35 MPH and depressing the brake pedal, the brake pedal went to the floorboard. The brake warning light was illuminated, and the check braking system message was displayed. Additionally, the check engine and ABS warning lights were illuminated. The contact activated the parking brake, and the vehicle came to a complete stop. The vehicle was towed to the dealer but no cause for the failure was found. The contact was informed that the caliper was leaking. The failure reoccurred and the vehicle was towed to the dealer. The contact was informed that the ABS unit needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and advised to contact the NHTSA Hotline. The failure mileage was 180,000.

The contact owns a 2010 Ford Fusion Hybrid. The contact stated while driving 20 MPH the vehicle lost braking functionality. The contact depressed the brake pedal and regained some braking power. The contact stated that several unknown warning lights were illuminated. The vehicle was taken to an independent mechanic who topped off the brake fluid and informed the contact to return in a week. The contact returned to the mechanic and the brake fluid was still full however, the failure recurred. The contact referenced TSB: 09-22-11 (Brake Controller) as a possible solution to the failure. The manufacturer was notified of the failure and referred the contact to NHTSA Hotline. The manufacturer was contacted and filed a case. The failure mileage was approximately 110,000.

The contact owns a 2010 Ford Fusion Hybrid. The contact stated while driving 25 MPH, the brakes became inoperable. The contact stated that additional pressure was needed to depress the brake pedal while slowing down and stopping. The parking brake and ABS warning lights were illuminated. The contact stated that the failure was related to NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic). The vehicle was towed to the local dealer, where it was diagnosed and determined that the failure was due to the ABS. The vehicle was not repaired. The vehicle was taken to an independent mechanic, who determined that the failure was due to the ABS. The manufacturer was contacted and opened a case. The failure mileage was approximately 130,000.

The contact owns a 2010 Ford Fusion Hybrid. The contact stated that upon coming to a complete stop, the brake pedal suddenly depressed all the way to the floorboard. The contact became aware that the brakes were no longer functioning properly. The vehicle returned to normal functionality, but the failure became a regular occurrence. The ABS and traction control warning lights were illuminated. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic). The manufacturer was notified of the failure, and a case was opened. The failure mileage was 100,000.

The contact owns a 2010 Ford Fusion Hybrid. The contact stated while driving 5 mph, the ABS warning light illuminated and braking functionality was reduced. The brake pedal was depressed to slow and stop the vehicle. The contact restarted the vehicle and the warning light disappeared. The contact stated that the vehicle started operating normally however, the failure recurred, and the contact pulled into a parking lot and had the vehicle towed to the local dealer to be diagnosed. The contact was informed that the ABS sensor needed to be replaced. The vehicle was not repaired due to the part not being available. The manufacturer was not made aware of the failure. The failure mileage was approximately 163,000.

The contact owns a 2010 Ford Fusion Hybrid. The contact stated that while driving at an undisclosed speed, the message "ABS fault Detected" was displayed, prompting the contact to discontinue driving the vehicle. The ABS warning light was illuminated. The vehicle was towed to an independent mechanic, who diagnosed a failure with the ABS Hydraulic Control Unit (HCU). The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 19V904000 (Service Brakes, Hydraulic), but the VIN was not included. The manufacturer was not notified of the failure. The failure mileage was 42,000. See DP26004 for potential Defect Petition DP26004

NHTSA investigations

Brake complaints in other Fusion Hybrid years