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 2016 Ford Fusion owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2016 Ford Fusion equipped with Michelin Tires, Tire Line: Energy Saver A/S, Tire Size: 235/45/R18, DOT Number: (Unknown). The contact stated while driving at MPH, the TPMS warning light illuminated. While the contact was attempting to pull over, the driver's side rear tire experienced a blowout. The contact was able to change the tire with the spare tire with the assistance of the local authorities. The contact later took the vehicle to an independent mechanic who discovered a nail in the tire which lead to the failure. The tire had been replaced. The tire failure mileage was approximately 20,000. The vehicle failure mileage was approximately 65,000.
The contact owns a 2016 Ford Fusion. The contact stated that the lug nuts were swollen and were unable to be removed. The vehicle was taken to the local dealer and the contact was informed that there was a defect with the lug nuts. The vehicle was repaired however, the failure recurred. The vehicle was taken to the same dealer for tire rotation and the contact was informed that the lug nuts were swollen. The contact declined the repairs. The manufacturer was notified of the failure and referred the contact to NHTSA but, provided no further assistance. The approximate failure mileage was 44,010.
The contact owns a 2016 Ford Fusion. The contact stated that the vehicle was at the dealer for a scheduled service appointment; however, the service could not be completed because the bolts were swollen. The contact was informed that the bolts for all four wheels needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to report the failure to the NHTSA Hotline. The failure mileage was approximately 22,545.
The contact owns a 2016 Ford Fusion. The contact stated that all four lug nuts were swollen. The contact stated while having a tire replacement by a towing company, the driver was made aware that there was an issue with removing the lug nuts. The vehicle was towed to the local dealer and the contact was informed to contact the manufacturer for assistance. The manufacturer was notified of the failure and referred the contact to the NHTSA. The failure mileage was 53,000.
The contact owns a 2016 Ford Fusion. The contact stated that upon taking the vehicle to the dealer for service, he was made aware that the driver's and passenger's side front wheel lug nuts were severely deformed. As a result, the dealer declined to complete the service due to safety concerns. The vehicle was not repaired. The manufacturer was notified of the failure but did not assist. The failure mileage was 120,000. The VIN was not available.
The contact owns a 2016 Ford Fusion. The contact stated that while the tires were being replaced, the dealer informed the contact that the lug bolts were swollen. Additionally, the dealer stated that if the lug bolts were removed, the bolts would be stripped and would need to be replaced. The lug bolts were not replaced. The manufacturer was not made aware of the failure. The failure mileage was approximately 40,000.
The contact owns a 2016 Ford Fusion. The contact stated that the factory lug nuts were swollen and difficult to remove the tires when needed. The contact had not spoken with a dealer nor a certified mechanic. The contact intended on replacing the lug nuts replaced with a better-recommended type. The vehicle was not repaired. The manufacturer was made aware of the issue. The approximate failure mileage was 67,490.
The contact owns a 2016 Ford Fusion. The contact stated while having an oil change performed at an independent mechanic, she was informed that the lug nuts were swollen. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 50,000.
On [redacted], Plaintiff [redacted] was in urgent need of replacing the front passenger side tire on his vehicle. He began searching online to compare automotive service providers, focusing on those offering competitive pricing and professional-grade installation. During my search, 1 came across Mr. Tire's website, which prominently displayed claims such as "Expert installation for less" and "Quality service for superior stopping power." According to their site, their tire installation package included: Tire mounting and wheel balancing Standard valve stem replacement TPMS inspection and reset Wheel alignment check Precision wheel torque by hand tools Lifetime tire rotation Lifetime rebalancing Believing this was a comprehensive and professional service package, I scheduled an appointment at Mr. Tire, located at 5 Bel Air South Parkway, Bel Air, MD 21014 (Store #771). …
The contact owns a 2016 Ford Fusion. The contact received notifications of NHTSA Campaign Numbers: 23V162000 (Service Brakes, Hydraulic) and 25V695000 (Back Over Prevention). The contact stated that the dealer had sent a mobile mechanic to the contact's residence to complete the recall repair of NHTSA Campaign Number: 23V162000 (Service Brakes, Hydraulic). During the day, the contact checked the residence ring camera and noticed that two mobile mechanics had stopped by the residence to work on the brakes. The contact stated that after a while, both mechanics left the residence and left the hood of the contact's vehicle lifted. The contact stated that the mechanic returned after a while and continued servicing the vehicle. The contact noticed that the mechanic had difficulty with the lug nuts on the wheels and had to fracture the lug nuts to remove the wheels. …
Wheel & Tire complaints in other Fusion years
Frequently asked questions
How common are wheel & tire problems on the 2016 Ford Fusion?
NHTSA has 46 complaints about the wheels & tires of the 2016 Ford Fusion, 3% of the model year's 1,644 complaints. The component named most often is lugs/nuts/bolts/studs (19 mentions).
Is there a recall for 2016 Ford Fusion wheel & tire problems?
No. NHTSA lists no wheels & tires recall for the 2016 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 2016 Ford Fusion wheel & tire problems start?
Half of the complaints with a recorded mileage happened before about 50,000 miles, and 23% 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.