Mileage when the problem started
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 that while in traffic on an incline, the hybrid battery was running however, the vehicle failed to accelerate. The message to "pull over safely, check charging system" was displayed. The vehicle was pulled off the road. The vehicle was towed to the local dealer to be diagnosed. The contact was informed that the wiring harness needed to be replaced because there was no power going to the vehicle. The vehicle was not repaired. The manufacturer was not contacted. The approximate failure mileage was 111,000.
While driving in traffic on a city street while traveling about 30 MPH the check engine light was on and a warning message to "stop safely now" appeared on the dash. Immediately, the car stopped accelerating. I still had power - lights, radio, heater - but could not accelerate and the car just coasted. I turned the key off and was able to restart the car, the warning was gone and then go about 5 car lengths before getting the warning again. I drove home (about 4 miles) and had to restart, coast and stop about 7 times. I was driving on a road where the speed limit is 35 MPH, made it home and continued to drive around in my neighborhood where there was no traffic, to see if it would continue. It happened 2 more times. Put the car in the garage and called webb Ford in highland, in the next day. Was able to drive the car 8 miles to the dealership with no incident. The car is there now. …
My Ford Fusion Hybrid 2010 stalled without any warning in the 5th lane of I-85 in atlanta. My wife, the responding police officer, and myself were in grave danger because of this. We were blessed and fortunate that an officer happened to be very close when our car suddenly died in the middle of the interstate. The interstate traffic was heavy - but slow moving due to construction. The officer responded - literally - within seconds since he saw what was happening. He placed his car behind ours with his lights flashing. The the officer and I had to push my vehicle off to the side. We were all in grave danger! As the officer was calling for help and a wrecker, my car suddenly began working after several minutes. This was an extremely dangerous situation. …
I have been requesting information from Ford about the recently announced cracking gas canister recall affecting my model vehicle without success. Media reports the recall includes 2010 vehicles made in hermosillo, Mexico. Ford did tell me that mine was manufactured there at the end of February 2010 and did say that mine was not included, but will not tell me what percentage of the vehicles built there during February and March 2010 are included in the recall. I have been corresponding with them via email for several weeks now and they continually evade answering my concern. The company's last message said the information I am requesting is not available. It is surprising to be told by a modern manufacturing facility like Ford that it does not know how many units it manufactured during a given period of time at a specific facility. …
First time, check engine light came on when driving on highway but no apparent impact to car's functioning. Took it to the dealer. They said that the surge valve needed to be replaced at a cost of $500 "to start with", but they didn't seem very sure about it so I chose not to proceed. The check engine light had gone back off and the car was driving fine. About two weeks later on a Saturday I was driving on the highway again, at about 65 MPH, when the car seemed to lose acceleration. Standing on gas pedal produced no result. Exited and was able to drive on battery power to pull over. After waiting for about 30 minutes, tried again. Check engine light was back off and car drove normally back home. Took to my regular mechanic first thing that Monday. …
Due to a design flaw, the car's computer system cannot accept an indication of more than one digit in the "age" entry. For this reason, the electric high voltage battery stops working when the car approaches 10 years of age, causing a serious and dangerous hesitation in the drive train when starting from a dead stop creating a very dangerous driving condition, especially when making a cross-traffic turn. Repeated requests from my Ford dealer to Ford motor company for an explanation of how to fix this problem were unsuccessful. My letters to Ford senior management have gone unanswered for several months. I have since learned how to reset the "age" data, and my dealer has followed the instructions to eliminate the condition. Ford should be required to issue a recall for correction of this known design flaw.
After approx. 25 miles of driving at 70 MPH, vehicle had sudden loss of power and dash displayed a red triangle warning to safely pull over now. After doing so and re-starting the car, the warning disappeared and vehicle was able to return to freeway speeds for a few miles before problem returned. While red triangle warning is displayed, vehicle is unable to maintain speeds greater than 35 MPH (aka "limp-home mode"). This appears to be a problem with the electronic throttle body and a consumer satisfaction program exists for the 2010 Ford Fusion but not the Hybrid model. Repairs seem to run about $400-$600 and May be difficult to diagnose unless the red triangle or yellow wrench icon is displayed during diagnosis. Problem re-appears intermittently but seems less likely to occur at city speeds.
The car stopped while driving through the free way@55 MPH. Do not accelerate. The engine vibrate and car shaking. After turn off and turned on the engine few times, the car was performing fine. The dealer checked. No malfunction code was detected. They told that 95% it is due to the clogging of electronic throttle valve. So replaced. I asked and they showed the old one. I observed no clogging or grease on the valve. It was clean. This parts/or throttle valve system was functioning. The car has 85,000 mile.I spoke to Ford about this safety issue. They don't do any because the warranty expire.
Driving at highway speeds, normal operation, in sunny conditions when I lost acceleration ability and was only able to coast. The yellow wrench indicator came on (no check engine light). I was fortunate enough to move to the should safely since there was limited traffic on the highway and I was driving in the right lane. I cycled the car off and on and was able to resume normal operation. This same situation happened twice more in city driving before I could get into the dealer for an appointment. Eventually the dealer evaluated the vehicle and replaced the electronic throttle body.
While driving at 65 MPH yellow wrench light appeared and vehicle lost all power. This was on a busy highway. Pulled over and restarted car. Vehicle operated smoothly. Two days later same issue, now with yellow wrench and check engine light. Vehicle will not accelerate above 30 MPH. I took my vehicle to local auto parts store and pulled codes myself (115) dollars cheaper then the dealership would have done it. Throttle body control failure. This is the same engine that has extended warranty for alot of VIN numbers but my car has this issue amd isnt covered.
Fuel System complaints in other Fusion Hybrid years
Frequently asked questions
How common are fuel system problems on the 2010 Ford Fusion Hybrid?
NHTSA has 40 complaints about the fuel & propulsion system of the 2010 Ford Fusion Hybrid, 8% of the model year's 509 complaints.
Is there a recall for 2010 Ford Fusion Hybrid fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2010 Ford Fusion Hybrid. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2010 Ford Fusion Hybrid fuel system problems start?
Half of the complaints with a recorded mileage happened before about 83,000 miles, and 5% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
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.