Swollen lug nuts. When attempting to get the wheels serviced, shops said they could not get the lugs off because they were corroding so a 19mm and a 20mm did not fit. There are other reports for this already.

- Baxter, MN, USA

My 2013 Ford Fusion experienced an electronic powered steering failure recently. It is my belief that this was due to an incorrect, incomplete, and ultimately unsafe repair to the affected system. From my research this model and year has experienced significant issues and failures of the "steering gearbox" even after the recall from Manufacturer Campaign Number: 19S26. Failures of the steering gearbox leading to an abrupt failure of the power steering system in the vehicle is not only incredibly dangerous but subsequently an issue what was not fully resolved by the organization. This vehicle has many foundational safety concerns that are a result of cheap and incomplete repairs revealing weaknesses in sustainable practices and beliefs held by the organization. When the issue arose it was abrupt and without warning initially. The vehicle is very difficult to control even at higher speeds with the failure of the electronic power steering gear box as compared to a traditional fluid based power steering system. When I had the vehicle inspected on 11/15/2022 I inquired from the ford dealership whether the work completed looked sufficient it was not answered. The employee also made note that this issue is "very common" and "very expensive to repair". As a result of this I am requesting that the NHTSA seriously review information and gather data corroborating information I have provided. I believe The Ford Motor Company needs to be held responsible for a full repair or provide assistance to those experiencing this issue to a part that if fixed properly would not be an issue under reasonable circumstance. Looking at the trends of this vehicle, its recalls, and its level of consistency of repair it has been extremely poor and unsafe. The most recent recall involving the seat belt has been "fixed" many times poorly resulting in another recall. This power steering gear box failure is build from the same clay and should be resolved through repair or repair based assistance.

- Columbus , OH, USA

I was told by the local dealership that the lug nuts are swollen and if not replaced will crack and cause risk to the wheels coming off.

- Sammamish, WA, USA

Lug nuts are swollen and required excessive time and labor at the Ford dealer to remove them and replace them. If I required road tire repair I would not be able to remove a tire. I was at dealer for oil change and tire rotation. Total time at dealer was 4 hours.

- Bonita Springs, FL, USA

The transmission keeps jerking and when waiting for a light to change car jerks. Also makes a noise that sounds like water boiling but it is something with the Moter.

- Lancaster, CA, USA

Lug nuts on wheels are swollen and cannot be removed with the wrench provided with the vehicle. This prevented me from being able to remove my flat tire and install the spare. I was forced to drive the car with the deflated tire to a mechanic in order to get it forcefully removed. This represented a dangerous situation

- Denville, NJ, USA

I purchased the car 4 months ago and discovered shortly after it was leaking coolant from a hose in the heating system. This external coolant leak was a 500$ repair. Earlier this week, my check engine light came on for the first time when I was in traffic on my way home from work. I was driving about 20 mph and heard a dull thud (I was told later this was probably my engine popping). I immediately took the car to a shop to have the code read (P0302). I scheduled an appointment at my local Ford dealership at 7 am the next morning (14 hours after the light came on). They diagnosed the car and called me to tell me there was an internal coolant leak in the engine and the only way to fix the car was a total engine replacement. They quoted me at 8500$ (more than the amount I purchased the car for) and told me multiple times there was nothing else I could do to fix it. I found out after my family checked out the car that the leak had caused a cracked head gasket and the spark plugs in the cylinder were contaminated from the coolant. The Ford ecoboost 1.6L engine has an open recall for causing engine fires because of an internal coolant leak, but they refused to acknowledge that the design flaw in the engine that cause coolant leaks led to the irreparable damage to my engine. They told me I could drive the car off the lot since I was not completing the repair there, but I couldn't make it out of the parking lot and had to have the car towed to my house. The car was shaking and the check engine light was flashing, which it had not been when I brought the car in. The engine is not safe and even if I were to fix it the design flaw would likely cause the problem to reoccur. Ford needs to acknowledge the engine is unsafe and pay to replace it with a newer engine that does not have the same flaws.

- Seattle, WA, USA

I have had repeated problems with this vehicle, and now it is on my credit record because it is beyond repair, and I returned it to the finance company where I purchased it from. I had to replace the lug nuts because the factory lug wrench wouldn't work, the engine ran hot (regularly) leading to long term engine damage, the transmission had been replaced twice since I began financing the car. The car only had 64K miles when I began financing it, by 77K, the transmission had to be replaced twice (first time in Dec.18, and then Jan.19), and it still shifted hard (at times) and still made a strange sound. I am involved in a class action suit over the transmission, but the repairs were aftermarket (and media indicates that even the manufacturer is not capable of fixing the problem) in approximately the month of may, 2019, the vehicle also would not start (key would not turn/no lights came on, etc.). I contacted the carmaker, and they had stated that they'd "never heard of this kind of issue before", but they did offer to purchase the vehicle back from me (at market value), but they became disinterested when I told them that I was financing the vehicle from elsewhere.

- Lockland, OH, USA

Replacement of lug nuts after 60,000 miles. The lug nuts are known to wear out and then need replacement at a cost of @$150. Makes no sense. I need to replace the fuel vapor separator (9D289). This will be the third one on this car at @ $400.

- Leawood, KS, USA

The lug nuts swelled causing us to have to purchase a special tool to remove them and then to replace all of the lug nuts to prevent any more issues. This is a well known issue with Ford, who will not correct the problem. There was a lawsuit on this.

- Weatherford, TX, USA

Had my oil change/tire rotation done on 08/01/19 and was told I had to get new lug nuts as they were swollen & misshapen. Cost of $200 to change them. I thought this is wi, winters are harsh so ok. Apparently this is not new according to this website. Also have no working airbags as a sensor for the seatbelt is not working. To fix that will be $300+ but I refuse to pay for this as there is a recall in place for that also!! we are loyal Ford customers and to find out Ford knows about this is infuriating. We are now looking to trade this Fusion in (only 75K miles on it) but do we go with another Ford or a different make. To have to even ask this question astounds me. Ford - fix the problems!!!

- Cascade, WI, USA

I just recently had to replace all of my lug nuts. Every lug nut had swollen so badly that they had to be replaced. One of the lug nuts broke clean off, while attempting to remove the wheel. Another lug nut was loose as a result of the defect. Ford knows about the problem, but refuses to do anything about it. It is a known serious defect, other Fusion owners I've talked to have said they have had a wheel fall off as a result of the lugnuts snapping.

- Clinton Township, MI, USA

Have yet to receive a notice of the takata airbag recall and now my light is flashing on while driving. I've had 2 diagnostics done on my car before I fixed the issue and after I replaced the ABS sensor on my left front wheel and I'm still getting the same codes for my ABS, service traction control and hill assist lights. I have had my brakes replaced thinking that was an issue because my pedal is depressing to the floor while in motion and feels like it won't stop when turning to park. What else am I to do?

- Palmetto, GA, USA

Swollen, misshapen lug nuts creates unsafe conditions for changing tires after a flat tire on the road. This is my son matthew's car and I am a co-signer on the title and pay the insurance. He noticed after getting a flat tire while driving in york, pa.

- Walkersville, MD, USA

Driving power steering light came on and lost all steering in the vehicle. Had to over power the wheel in order to get to a safe spot.we were in the city driving.

- Madison, OH, USA

Vehicle seems to have a humming thumping noise and vibration when ran on speeds over 40 mph. Initially I thought the tires had gone bad, and ireplaced all four of them as well as the lug nuts due to swelling and got the vehicle realigned at a good year service center. After the process was completed I drove and car and the same noice as well as vibration persisted. It can be felt on the drivers side on the floor as well as the break and gas pedal at times. Tsb 16-0105 highlights the issue, but only for hybrid electric models.

- Plainfield, NJ, USA

Today I visited my local tire store to have my tires balanced and rotated and I was notified by the technician that my lug nuts are swelling and delaminating which could result in me being stuck on the side of the road and not being able to remove the lug nuts with the provided wrench for flat tires. I'm considered about my safety when an event like such may occur.

- Conroe, TX, USA

Have had to have the lug nuts replaced twice. The most recent replacement was with 32,000 miles on them. Was told by dealer that the lug nuts were "swollen". this swelling results in the lug nuts not being able to be removed with a standard wrench. If this occurs when driver has a flat tire, they may not be able to remove the tire to change it and would result in the car being towed to a repair shop just to change a tire. My car is under warranty, yet the dealer charted me to replace the lug nuts. Have researched "swollen lug nuts" and this seems to be a problem with Ford. The swollen lug nuts were discovered during a routine oil change.

- Edison, NJ, USA

I was driving approximately 20 mph on a city street when the right front wheel fell off the car, causing me to lose control of the vehicle. Had I been moving faster, the failure would been far more serious and would have very likely resulted in death or injury. The wheel fell off the car due to a failed ball joint even though the vehicle only had 67,120 miles, had received regular maintenance, and had not been in an accident. Ford denies any responsibility for the failure although it seems obvious that the wheel of a four year old car with relatively low mileage should not simply fall off the car.

- Maple Grove, MN, USA

The aluminium lug nut caps swell so the lug wrench supplied with the car can not remove the lug nuts. Tow truck could not remove them so car had to be towed to dealer, short-redmond 1916 jacksboro pk. Lafollette, tn 37766, (800) 810-9088, www.short-redmondford.com. the dealer said this is a common problem with the Fusion lug nuts and other lug nuts of the same type. The dealer got the lug nuts off, but they had to be replaced at a cost of $52/tire. My dealer in asheville, nc also advised my to replace the lug nuts the next time I had my tires rotated, but said not to buy them from Ford. There are solid steel/chrome after market lug nuts that are better then the aluminium capped lug nuts that Ford uses. This is clearly an engineering issue. It did not allow me to change a tire on the side of the road with the equipmnet supplied with the car. I had to wait over and hour on the side of an interstate highway for a tow truck which is also unsafe. I do have the lug nuts as well as reciept from for to remove and replace the lug nuts. The aluminium lug caps are very deformed since they had to hammer a socket onto them to get them off.

- Fletcher, NC, USA