Fuel System complaints by model year
Mileage when the problem started
What owners report
The contact owns a 2018 Ford Fusion. The contact stated when the vehicle was started, the instrument cluster display failed to illuminate. The contact stated that the cluster had intermittently lost functionality. The contact stated that he researched online and related the failure to Technical Service Bulletin Number: 20-2363 APIM module. Additionally, the contact stated that the fuel filler pump and fuel door actuator had started to lose functionality. The contact stated that he was unable to completely fill the fuel tank. The contact stated that the check engine warning light was illuminated. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the APIM module needed to be replaced and that the fuel filler pump and fuel door actuator need to be replaced. The vehicle had not been repaired. The manufacturer had been informed of the failure. …
On May 26, 2023, after I started moving from stop at a traffic light, I rear ended the vehicle in front of me when it came to a sudden stop. My speed was between 25 - 35 mph at most. My front and side curtain airbags deployed, the hood was crumpled and fascia was damaged as expected. However after 10 minutes or so, flames started coming from underneath the hood and within a few minutes the engine compartment was on fire. The Fire Department arrived and put out the fire but had to break the windshield and rip off the fender to aim the fire hoses.
Auto shuts down while driving,no power..must stop,shut off ignition and restart the engine...car seems to revert to normal after turning back on.has occured many times..local Ford dealer is aware of problem and has installed a counter..the counter clocks up when this occurs but resets when car is stopped and restarted...this is a potentially dangerous problem as this has happened in traffic and driver has no power,must pull out of traffic,restart and go again...
While using full accessory power with the engine off, the car will allow you to change the gear shift dial to drive. The car is able to move in this position, but the gas pedal will not work. The 'ready to drive' light is.not on.
Driving down rural residential area road at night. Car illuminated "stop safely now" warning and lost power. Car stalled and would not re-start leaving me stranded. Tow truck was called and picked up car. Dealer reported that car blew 125 amp fuse and several electrical components damaged. This occurred approximately two weeks after car's leaky transmission was repaired. Car still in service department.
Emission recall14e02 which states vet May be equipped with an improperly functioning on-board emission-related diagnostic system that does not meet california standards and regulations, which also apply in massachusetts, maine, new york and vermont. Disabled emission-related monitors are unable to warn of an emission control malfunction. Vehicle when being operated smells and causes occupants to choke.
The contact's granddaughter owned a 2013 Ford Fusion Hybrid. The contact stated that while her granddaughter was driving at an undisclosed speed, the driver looked in the rearview mirror and noticed black smoke coming from the rear seats of the vehicle. The contact stated that the driver's sons were in car seats in the rear seats of the vehicle. The driver immediately pulled over to the side of the road, exited the vehicle, and took her sons out of the vehicle. The contact stated that the entire vehicle then caught on fire. The contact stated that the driver's side of the vehicle was more burned than the rest of the vehicle. The fire was extinguished by the Fire Department, who informed the contact's granddaughter that the fire might have originated from the trunk of the vehicle. It was unknown whether a Police report or a Fire Department report was filed. …
My vehicle - from a stopped position - accelerated on its own to 40 MPH (rather quickly). However, the gas pedal was not engaging (ie. Depressing). This occurred at lunchtime on 17-jun-2016. All trouble lights on the dash lit-up. The behavior continued until I shut the vehicle off at the dealer (elder Ford in troy, mi). I was unable to engage the throttle at all; it was essentially 'dead', even though my vehicle was accelerating to 40 MPH and maintaining that speed. Braking response was diluted because the car was self-propelling (imagine trying to brake while also applying gas). I took it to the dealer immediately and showed them the videos that I took. I also sent the videos to them. I have been told today that they will be giving the vehicle back without any repairs because they could not replicate the problem. I have the videos in my possession, should NHTSA like to see them. …
Frequently asked questions
Which Ford Fusion Hybrid years have fuel system problems?
By NHTSA complaints, the 2010 (40) and 2013 (9) model years. Fuel System complaints make up 8% of all complaints for the 2010.
Is there a recall for Ford Fusion Hybrid fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for any Ford Fusion Hybrid 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 Hybrid fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 67,000 miles; 43% happened before 50,000 miles.
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.