Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2012 Ford Fusion owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2012 Ford Fusion. The contact stated that while the vehicle was parked, the driver's side door failed to open using the interior door handle. The vehicle was taken to the dealer where it was diagnosed and determined that the driver's side interior door handle needed to be replaced. The vehicle was repaired but the failure reoccurred three years later. The contact stated that on the second occasion, the driver's and front passenger's side windows were rolled down and the door was opened using both outside door handles. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 116,945.
The contact owns a 2012 Ford Fusion. The contact stated while attempting to exit the vehicle through the front driver's side door, the door handle fractured. The contact was able to use the remaining part of the door handle to exit the vehicle. The vehicle was not taken to the dealer to be diagnosed or repaired. The manufacturer was not contacted. The failure mileage was 31,000. The VIN was invalid.
Over the past few days driver side door would not open from the inside of the vehicle. Rolling down the window and opening the door from the outside is the only option in opening the driver side car door. This is a safety concern as if I were ever in need to exit the vehicle in an emergency manner I can not easily or quickly get out of the car we're under water, on fire, etc. My vehicle is not the only vehicle that is having this issue, I have heard reports from mechanics, other Ford Fusion Drivers, and personal experience that Ford Fusions from about 2006-2013 are having this issue. The issue needs to be addressed for safety concerns and is only happening on the drivers side door.
Front Driver Side door handle mechanism breaks and will not open the door when the lock mechanism is in the Unlocked position. To open the door from the interior, the driver must roll down the electrically-powered window and use the exterior latch to open the door. There are multiple examples of these situations and the owner's description of repairs. Here is one example: https://youtu.be/At96DIaPyc8 This is a serious and significant safety hazard for the vehicle driver, particularly in the event of a vehicle fire or water submersion.
Driver side door handle from interior failed and no longer works. Live in South Florida and believe heat caused plastic component to break. Unable to exit vehicle unless use 2 hands...one to pull back on locking mechanism and other hand on door handle. Internet search shows common issue with 2006-2012 Ford Fusion models. Many state they roll down window and pull exterior door handle to exit vehicle. Seems like safety hazard if one needs to exit vehicle in a hurry.
Driver door is not locking. Tried with manual key too but not successful. Tried to open door from inside but no success. Looks like door assembly or spring is faulty and designed poorly This can be a safety hazard as driver can't get out of car easily. Pls recall all Ford fusion 2012 and ask dealers to fix it. I checked few articles forums and YouTube videos and everywhere it says there might be a spring problem or some plastic issue in latch or door assembly.
This is the second time my door latch has malfunction. I'm a single parent and to keep having to come out of pocket to get the same issue fixed is a big inconvenience.The inside is broken I have to roll my window down and unlock my door from the outside just to get out of my car. This is a major safety hazard why hasn't the recalled 2012 Ford fusions been included for the door latches? I can't even lock my door and there has been numerous break-ins close by.
Door handle open mechanism failed (of driver side door) thus causing a safety issue because you cannot exit the vehicle when inside, except by rolling down the window. This issue has been reported by several other owners.
Absolute unacceptable level of rust to the body and frame. Even with regular car washes, sitting for a year covered. It's literally totalled and I am out of a car. It's a 2012 with this amount of rust
Tl* the contact owns a 2012 Ford Fusion. The contact stated that after attempting to exit the vehicle, the interior driver side door handle fractured. As a result, the contact sustained a hand injury that required medical attention. The vehicle was taken to the dealer where it was diagnosed that door handle needed to be replaced. The vehicle was repaired. On another occasion, the contact stated that while driving approximately 40 MPH and attempting to avoid crashing into an animal in the road, the steering wheel seized without warning causing the contact to crash into the animal. A police report was filed and there were no injuries reported. The vehicle was not diagnosed but the body damage was repaired. The manufacturer was notified of the failure. The failure mileage was 50,000. Updated 12/01/15
Body complaints in other Fusion years
Frequently asked questions
How common are body problems on the 2012 Ford Fusion?
NHTSA has 99 complaints about the body & structure of the 2012 Ford Fusion, 4% of the model year's 2,517 complaints. The component named most often is body (75 mentions).
Is there a recall for 2012 Ford Fusion body problems?
No. NHTSA lists no body & structure recall for the 2012 Ford Fusion, though it has 5 recalls for other components. 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 2012 Ford Fusion body problems start?
Half of the complaints with a recorded mileage happened before about 66,000 miles, and 9% before 25,000 miles.
Is it dangerous?
Owners linked 13 crashes, 0 fires and 8 injuries to body & structure 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.