Which parts fail
Components named in complaints (wheels, lug nuts, original-equipment tires, TPMS).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2015 Ford Fusion owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2015 Ford Fusion. The contact stated while the vehicle was at the dealer for a scheduled tire rotation, the contact was informed that the lug nuts were swollen. The contact was informed that the lug nuts needed to be replaced. The vehicle was repaired. The contact stated that a torch was used to remove the lug nuts. In addition, the contact was informed that the failure was a known issue. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 40,000.
The contact owns a 2015 Ford Fusion. The contact stated that the lug nuts on all four wheels were corroded and swollen. The contact was concerned that in the event of a flat tire or blowout, the lug wrench would be unable to remove the swollen lug nuts. The vehicle was taken to the dealer where it was diagnosed that all the lug nuts needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 52,000.
The contact owns a 2015 Ford Fusion. The contact stated that the driver's side front tire lost air and became flat, but the independent mechanic was unable to remove the wheel from the vehicle due to the lug nuts being swollen. The vehicle was later taken to the local dealer who replaced the lug nuts. The cause of the failure was not determined. The manufacturer was not yet contacted. The failure mileage was 48,000.
I was driving on the freeway yesterday, about 70mph driving conditions were good, it was sunny and warm, and traffic was flowing regularly, and I felt as thought something gave way or loosened up because the car and steering ability were not in synch. I was then approaching a congested area and needed to slow down but the brakes did not brake as fast as they should of and I almost smashed right into the car in front of me. There felt like a disconnection between the brakes, the steering, and the entire car. I have keep my care well maintained and do not miss my regular maintenance appointments. I just had it smogged, with a change of oil and 80k inspection. The tires were checked and everything was ok. There were no indicator lights or alerts however, I do have a light that will not shut off and i was told subject to a recall. It's the front fog lights? or running lights? …
Took vehicle to Ford dealership for routine maintenance 5 June 2024. At end of servicing, service advisor reviewed findings of the multi-point inspection with me (attached), advising all wheel lug nuts (20) on the vehicle were "swollen" and needed to be replaced; failure to do so will result in being unable to remove any wheel in the event of an emergency, i.e., flat tire, as the provided 19" lug nut wrench ( or any substitute 19" socket will not fit). Quoted price of $337.60 for nuts ($447.52 incl labor). I passed. Ordered one piece chrome lug nuts (20) for $40, and a $45 half size socket set (19.5mm) online and changed them myself. Research on the issue reveals Ford is aware of this safety defect of two piece swelling lug nuts, yet refuses to recall affected vehicle or remedy the safety issue. …
To keep it short. This is 1 of 3 Ford vehicles that I had to pay to have every lug nut replaced! They are 'swollen' is the term used. Prior to this, I replaced 1 lug in my 45 year driving history and that was because it broke off. I have called Ford and Lincoln and they are aware of the problem but say there is not program in place for a resolution. My complaint was escalated I was told. Hahaha. Their hand needs to be forced. They are not going to willingly do the right thing going forward nor address refunds! They have 'escalated' all 3 of my issues. I would imagine that there is a fourth coming at some point when my daughters car needs to go into the shop. $250+ a car is a joke and an expense nobody needs. Please help. [redacted]
Car was taking him for a recall on brake lines. Dealer phoned me and suggested that they replace the Lugnuts because they are a two piece. They are swollen and it's a safety issue. I agreed to have them replace them at my cost because there is no warranty on these defective Lugnuts I see that this is an ongoing issue that Ford has known for quite a while. I think they should reimburse the people for the money they have spent on the dealer charges or just warranty them for the rest people that come in with the same issue. I also believe that my dealer is way over charging 10 Lugnuts will be about $100 for me to pay whereas I can buy a set of 20 of them online for under $20. I think this is outrageous.
When taking my car in for regular servicing, I was told that the tires could not be rotated because of swollen lug nuts. My vehicle has 11,777 miles. Without proper tire rotation, I cannot effectively drive safely without risk to myself and others. So, I opted to have the lug nuts replaced in fear of future problems should I need to remove a tire. Not being a mechanic, I have no idea what constitutes the look or feel of swollen lug nuts. My car was serviced on March 12 and 13, 2024 at the cost of $381.86 (lug nuts: $257.35)
Took my car to the dealership for an oil change and tire rotation. The technician told me they cannot get the tires off to rotate them because the tire lug nuts were swollen. He asked me if I wanted to replace them. I agreed after he said that if I were to get a flat tire it would be hard to get it off to fix it. Basically, this issue became a safety one. I never had an issue with swollen lug nuts with previous cars I had own. Thank you for gathering these type of issues.
235/45R18, the tires wander on grooved highways (groove wander). They throw the car left and right. This is a safety concern as it creates dangerous instability. Looks like the tire tread is incompatible with some road surfaces (grooved highways) and creates a safety hazard (car violently swerving at highway speeds). Wheel balancing and alignment was done to eliminate these as potential contributors. The store refuses to accept the tires for a return.
Wheel & Tire complaints in other Fusion years
Frequently asked questions
How common are wheel & tire problems on the 2015 Ford Fusion?
NHTSA has 26 complaints about the wheels & tires of the 2015 Ford Fusion, 3% of the model year's 997 complaints. The component named most often is lugs/nuts/bolts/studs (7 mentions).
Is there a recall for 2015 Ford Fusion wheel & tire problems?
No. NHTSA lists no wheels & tires recall for the 2015 Ford Fusion, though it has 13 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 2015 Ford Fusion wheel & tire problems start?
Half of the complaints with a recorded mileage happened before about 52,000 miles, and 10% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 0 injuries to wheels & tires 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.