Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2018 Ford Fusion owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2018 Ford Fusion. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic and was diagnosed with a failed EVAP purge system. The contact was informed that the EVAP purge system needed to be replaced. The vehicle was not repaired, and the failure reoccurred. The contact stated that the fuel tank made a vibrating sound before the vehicle stalled. Additionally, the contact stated that after refueling the vehicle, the vehicle failed to restart immediately. The contact stated that the vehicle restarted after several attempts. The dealer was contacted and made aware of the failure and a service appointment was scheduled. The manufacturer was made aware of the failure and a case was filed. The failure mileage was approximately 79,000.
The contact owns a 2018 Ford Fusion. The contact stated that while driving or while stopped at a traffic light, the vehicle stalled. The vehicle was sputtering while driving at various speeds. The check engine warning light was illuminated. The contact stated that after refueling, the vehicle failed to restart. The vehicle was taken to an independent mechanic, who informed the contact that the failure was due to the canister purge valve. The vehicle was taken to the local dealer, where it was diagnosed that the canister purge valve was stuck. The vehicle was not repaired. The manufacturer was contacted and opened a case. The failure mileage was approximately 113,000.
The contact owns a 2018 Ford Fusion. The contact stated that after starting the vehicle and driving from a complete stop, the vehicle made abnormal rattling sounds. The contact stated that the failure ceased while driving 40 MPH however, the failure recurred while driving below 40 MPH. There was no warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed that the flywheel was fractured and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 80,000.
The contact owns a 2018 Ford Fusion. The contact stated while driving 30 MPH, the vehicle stalled with the check engine warning light illuminated. The vehicle was able to be restarted; however, the failure persisted. The contacted stated that the failure persisted, and the vehicle would not restart. The vehicle was taken to an independent mechanic where it was diagnosed as a malfunction with the gas cap. The contact was informed that the gas cap needed to be replaced. The dealer was not contacted. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 73,000.
The contact owns a 2018 Ford Fusion. The contact stated that while driving at an undisclosed speed, the check engine warning light was illuminated. The vehicle was taken to the dealer where it was diagnosed that the EVAP valve failed and needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 71,000.
The contact owns a 2018 Ford Fusion. The contact stated that while starting the vehicle and shifting into reverse(R), she was unable to shift between gears. There was no warning light illuminated. The vehicle was towed to the residence. The vehicle was then towed to an independent mechanic, where it was diagnosed that the under hood shifter cable bushing needed to be replaced. The vehicle was repaired. Additionally, the contact stated that the vehicle was taken back to the mechanic for routine oil change service; however, while driving at an undisclosed speed, the check engine warning light was illuminated. The vehicle was taken back to the independent mechanic, where it was diagnosed that the canister purge valve (CPV) needed to be replaced. The contact stated that the part was replaced; however, the vehicle stalled after being refueled. …
M 19 year old daughter purchased the 2018 Ford Fusion 1.5L FWD certified on May 10th from AutoNation Ford of Orange Park, FL on 5/10/2023. Car broke down on 7/31/23 at 93032 miles and had it towed back to AutoNation. Was told that the flexplate broke and that there was coolant intrusion in one or more cylinders. Had the car repaired using the extended warranty plan that was purchased for the engine repair. Also paid to have the flexplate replaced. Received the car back on 9/22/23 with 93041 miles. On 9/26/23, check engine light at 93173. Code read oxygen sensor and emission purge valve sensor. Did not have repaired right away so that we can save up for the cost since it wasn't covered by the extended warranty plan. The cost was going to be about 700.00. Then the car started to hesitate in traffic while making a loud "farting" noise and eventually breaking down on 11/8/23 . …
I went on a road trip to see family which needed 5 hours of travel. After returning and parking the car, I noticed a knocking noise coming from the engine bay when it was started and was idling. After doing what I could to rule out possible problems I concluded the Flexplate might be the culprit due to Recall 22N12 with Ford. A short time later, my car started to stall if I did not keep my RPM's high enough while my vehicle was stopped. After getting an inspection done with a dealership they confirmed that it is the Flexplate. The symptoms gradually got worse which is what ultimately led me to bring it in to a dealership instead of a different shop. The problem is that this repair estimate I got says this repair is going to cost me $3,000. I am arguing that my vehicle should have been on Recall 22N12. …
Formal Complaint - 2018 Ford Fusion 1.5L EcoBoost - Engine Block Defect Statement of Issue:I am writing to report a premature engine failure on my 2018 Ford Fusion 1.5L. The vehicle is exhibiting all symptoms of the well-documented "coolant intrusion" defect described in Ford Technical Service Bulletin (TSB) 22-2222. Despite following all recommended maintenance intervals, the engine block has failed, allowing coolant to enter the combustion chamber.Observations:Confirmed coolant loss with no external leakage found via pressure test.Significant white smoke and rough idle upon cold start. Desired Resolution: Since this is a known manufacturing defect involving the engine block's cooling channels-and not a result of wear and tear-I am requesting a "Goodwill Repair" for a long-block replacement. …
I would like to respectfully request that my 2018 Ford Fusion, with the 1.5L EcoBoost engine, be considered for inclusion in the customer satisfaction programs related to the engine issues I'm experiencing. Despite my vehicle not being initially listed, the problems I've encountered, including the diagnostic trouble code P0302 and the coolant leak into cylinder #2, suggest that it may be suffering from a similar defect or design flaw that the program aims to address. Given the safety risks associated with the current condition of my vehicle, I believe it would be fair and reasonable to include it in the program and provide the necessary repairs or replacements to ensure the vehicle is safe to operate. I would appreciate your assistance in facilitating this process and exploring options for resolving this issue in a manner consistent with the treatment of similar vehicles.
Fuel System complaints in other Fusion years
Frequently asked questions
How common are fuel system problems on the 2018 Ford Fusion?
NHTSA has 30 complaints about the fuel & propulsion system of the 2018 Ford Fusion, 7% of the model year's 442 complaints. The component named most often is kinetic › flywheel,bearings (2 mentions).
Is there a recall for 2018 Ford Fusion fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2018 Ford Fusion, though it has 2 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 2018 Ford Fusion fuel system problems start?
Half of the complaints with a recorded mileage happened before about 73,000 miles, and 29% before 25,000 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.