pretty bad
Typical Repair Cost:
Average Mileage:
78,250 miles
Total Complaints:
15 complaints

Most Common Solutions:

  1. not sure (8 reports)
  2. replace throttle body (3 reports)
  3. replacement of wiring harness (3 reports)
  4. my evap control solenoid valve was stuck open allowing fuel (1 reports)
2010 Ford Fusion Hybrid engine problems

engine problem

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2010 Ford Fusion Hybrid Owner Comments

problem #15

Jul 092019

Fusion Hybrid 3.2L

  • Automatic transmission
  • 68,700 miles


We had lots of wiring and the full engine harness replaced which the dealer said had been chewed by an animal. I have since talked to a woman who had the same car and year as we have, who said she had exactly the same problem we had, and with the same kind of high bill. I looked online and it is clear that the first two years of this model have these issues. Some the Ford company covered and most not.

I feel from my research and experience that this was definitely not animal damage but the same problem described by others. I trust my repair guy but I think he was lead astray by Ford. The problem has continued and we are on our 4th repair when the car stops and has to be towed in to the dealer. As regards animals such as mice, we do not have them as we keep poison out at all times for rats and mice.

- Tangela P., Portland, OR, US

problem #14

Feb 132020

Fusion Hybrid 3.2L

  • Automatic transmission
  • 68,963 miles

Towed again. This one was covered but all the time is takes to get a repair and to have no car is not good. This was an engine wrench light problem that died while driving.

- Tangela P., Portland, OR, US

problem #13

Feb 022019

Fusion Hybrid

  • Automatic transmission
  • 109,000 miles

Car warning light came on, pulled over and car died. Waited a few minutes and drove about half a mile and it happened again. Car towed to dealership and worked just fine. I was told it could go out anytime or not happen again. I was quoted $15,000 to replace the engine. I asked how much is it worth as a trade in and told $2,000. I knew something was up. Who is going to give anyone $2,000 on a 2010 car with 109,000 miles and a $13,000 repair needed? NO ONE. So glad I found this site and will inquire about replacing the throttle body for $500.00!!!

- Debby C., Visalia, CA, US

problem #12

Aug 152018

Fusion Hybrid

  • Automatic transmission
  • 137,000 miles


Similar to other Fusion stories, my hybrid ran great for 8 years then suddenly lost power in the middle of an intersection, no response to the accelerator and the triangle (PULL OVER NOW) light came on. Car could be restarted. But then occurred again very shortly after. Towed to Dealers. They replaced Throttle body and Purge Valve. Paid $500. Drove fine for one evening, but next day did the same thing again. Very Dangerous. Fortunately I was not on a highway. Towed again to dealers. They are saying that Ford is not responding to requests for help with a fix. So it has been 6 days and counting. Very Frustrating. I empathize with the rest of you who have had this problem.. Can anybody suggest how to really fix it????

- Sharon K., Bear, DE, US

problem #11

Aug 192017

Fusion Hybrid

  • Automatic transmission
  • 88,108 miles

My wife and I - along with the responding police officer - were in grave danger in the 5th lane of I-85 in Atlanta.

My car suddenly - and without any warning - stalled with a wrench light illuminated on the dash! There was no way for me to get over to an emergency lane.

Thankfully, a police officer happened to be there immediately when our car died in the middle of the interstate. Literally, within 5 seconds since he was on the road near me. He came to our rescue by placing his car behind ours with the emergency lights. Then the officer and I had to PUSH my car to the side of the road. We were all in serious danger.

The officer was calling for a wrecker and assistance. Then suddenly my car restarted after several minutes.

I then began looking into this problem and discovered on the internet that many other customers have also had this happen to them. This is totally unacceptable! Ford needs to recall these cars immediately before a tragedy occurs. This is extremely dangerous.

- Brendan M., Suwanee, GA, US

problem #10

Jun 112016

Fusion Hybrid Hybrid 2.5L

  • Automatic transmission
  • 71,000 miles

Ford Fusion Hybrid's engine shuts off while driving on the highway. Warning message displays saying 'stop safely if you can'. Car goes from 60 mph to about 20 mph in a few seconds. Pull over the side of the highway. Turn of the key for a few minutes. Start the car and the car starts ok as if everything is ok. Same thing happens about 5 times on the way home. Very dangerous. Dropped off the car at the dealership. Have not received word yet of what the problem is.

- dchege, Washington DC, DC, US

problem #9

May 212016

Fusion Hybrid

  • Automatic transmission
  • 116,000 miles


My husband was driving on the freeway and the car engine cut off and went into safe mode. He was able to pull over and turned the car off and back on. The deal said the it would be 10,000 to fix which is totally ridiculous because we paid $8000 used. No we are having other electrical issues with the braking cutting out and the car cannot be driven. I have a parked car - no way to fix it and the Ford Customer Service is no help. There were 12,000 car with the exact same issue so Ford offered a customer service to fix for free to some limited VIN numbers but mine is apparently not covered. What a piece of trash.

- Lynnette C., Woodland Hills, CA, US

problem #8

Dec 292016

Fusion Hybrid 2.5li4

  • Automatic transmission
  • 93,192 miles

I submitted below to Owner.Ford.com and they said it is not covered under warranty or customer satisfaction but that they would submit it for review by appropriate department:

I am wondering why I had to pay the full charge of $466.14 for throttle body replacement on 12-29-16 based on the following:

I have a 2010 Ford Fusion Hybrid 2.5L I4 EUV Engine with 93,192 miles. When I bought the car, I paid for the Premium Maintenance Plan for $1,150 (up to 75,000 miles). At 85,000 miles, I paid for the 90,000 mile scheduled maintenance. All car service (even battery and tires) was done at the Ford Dealer where I bought the car and I have enjoyed all my service trips there until now.

As I was paying, I talked to the Service Manager, who advised me that the throttle body inspection and cleaning is only done as part of optional induction service. I told him I looked through my service invoices and my multipoint inspection report cards and could not specifically see that any maintenance was ever done to the throttle body. Also that 1.6 million cars with another Ford 2.5 L engine were having throttle bodies covered under a revised warranty up to 150,000 miles. Also that I was complaining to Ford.

Once I got home I further discovered that: 1) number 1 complaint for 2010 Fusion Hybrid on carcomplaint.com is engine stalls/dies while driving with throttle body most sited as the reason 2) there are no technical service bulletins for this engine problem 3) periodic visual inspection and cleaning (if necessary) are recommended for the throttle body based on my internet research 4) there is nothing about throttle body maintenance on genuine service.com.

Accordingly, I don’t believe I should have had to pay a full charge of $466.14. Further that you consider clearly addressing periodic throttle body visual inspection and cleaning in your customer service processes and documentation.

- Joseph N., Columbia, MD, US

problem #7

Aug 142016

Fusion Hybrid Hybrid 2.5L

  • CVT transmission
  • 53,000 miles

click to see larger images

engine stalls/dies while driving engine stalls/dies while driving

Problem has now occured three times within two days, once while leaving gas station after fuel-up and then the following day while on the interstate with minimal traffic and then while exiting interstate. In all instances there was a red triangle that informed me to pull over and stop. The first time it happened a restart didn't solve the problem and i was able to drive on electric back home where i attempted another restart and it started and ran normally the remainder of the day. The following day after both stalls i was able to restart the car after a complete stop. I bought this vehicle used three weeks ago with 50,000mi on the odometer. I have put 3000 miles on in that short amount of time. Untill these problems i have praised the automobile for every quality it had. I am not impressed ford. This is my first american vehicle in several years and i am very disappointed. How can we compete as a nation if we cannot put out a good product and then stand by that product. I hope there is a fix in the works.

Update from Aug 16, 2016: Ok, i bought a used vehicle. I understand there are sometimes maintenance issues that need to be addressed with any used car. With this problem no codes were thrown and an ignition switch cycle would generally reset the problem. After witnessing several more failures i began to notice it wasn't an engine stall. The engine was not restarting after the hybrid system shut it down to coast. It's time for a service manual. I began parts replacing because i'm on the road and need the car to be mobile. First i replaced the throttle body with no change in the problem. Next i replaced the fuel pump relay/module. I did not have any problems the remainder of the day (300mi) after the replacement of the fuel pump module. Ford Part #aa8z9d370b This part is in the trunk on the driver side behind the side carpeting. It cost $65.00 and took five minutes to replace. If the problem persists i will update the solution. Until then i'm calling it fixed.

Update from Aug 20, 2016: Happened again today immediately after fuel-up. It has happened three times now immediately following fuel up. Today was the first recurrence of the problem since fuel pump module replacement. Ford is making money on me.

Update from May 13, 2017: Fixed stalling issue. My EVAP control solenoid valve was stuck open allowing fuel vapor to be continuously drawn in by manifold vacuum. A code was eventually thrown by the computer for the EVAP system. I verified valve was stuck open. Instead of ordering and installing a new solenoid valve i squirted a common household lubricant into the part and beat on it gently. No more Stalling.

Update from May 13, 2017: vehicle now has 70,000 mi and since lubing the evap solenoid valve i haven't had any problems.

- alfonzo27, Port Charlotte, FL, US

problem #6

Jul 122016

Fusion Hybrid SE Hybrid

  • Automatic transmission
  • 55,000 miles

My 2010 Ford Fusion Hybrid stalls at highway speeds and slows down to about 40 mph. This is very dangerous and could cause an accident if I was not able to pull off the road. Then, when I turn off the motor and restart the engine it runs fine. I called Ford corporate and they told me to have the dealer plug it in to their diagnostic computer. I did so and the dealer told me the computer shows no record of a problem. I spoke with the Ford regional office and they told me that they will not assist in finding a solution. This car is too dangerous to drive and I may have to buy another car, certainly not a Ford. I note that other Fusion owners have reported this same problem Can anyone help?

- William B., Charleston, SC, US

problem #5

Jul 132016

Fusion Hybrid

  • CVT transmission
  • 73,603 miles


I had had the car in to the dealer twice in the past week for a clattering sound upon acceleration at low rpm and the yellow wrench light. They had replaced the electric water pump and an idler assembly (for $967), neither of which solved the issue. I continued to drive the car for a few days, and the wrench light had not come on, although the low "clattering sound" continued while accelerating. However, on July 13, we took a trip of about 30 miles or so...during an uphill grade (while the car was clattering), it suddenly DIED...right in the 3rd lane of a 4-lane freeway! This time the display showed a red triangle and said said: "Pull over and stop safely." (Actually, I had no choice). I expected to be towed, but once I was on the side of the freeway, I turned off the key, turned it back on, and guess what? The green light came on, and the car ran as if nothing had happened. No other adventures that day except that the yellow wrench came on agin as I was returning home. I have read on this site about throttle body issues, recalls, and "customer service advisories."

I took the car back in this AM and let them know that I consider this a severe safety issue, and that I had been lucky to be able to "drift" to the right shoulder of the freeway this time. I also asked about recalls and the Ford "Customer Satisfaction Program" on the throttle body issue. They could find nothing about any of it...so now, the car is back in the shop, and they're gonna let me know what they find out...

Although I loved this car, I have suddenly lost all confidence in it AND the dealer. If they say I need to invest another $900 for a throttle body or something, I'm just going to have them close it up, and I'll trade it in on a Toyota or something.

- Roy N., Bloomimgton, CA, US

problem #4

Jul 092016

Fusion Hybrid Hybrid 2.5L 14 Hev

  • CVT transmission
  • 87,700 miles

Had an issue with loss of power on the freeway, (very dangerous). Called Ford Motor Company before I called the dealership. The Company took my info but told me nothing, they said my complaint would be on file and connected me with the NHTSA and I gave them a report. Took the vehicle to the dealership and they diagnosed it to be the Electronic throttle body (ETB) and said it would be covered on an extended warranty for that issue. The part is supposed to come in today (two days after diagnosis). I'll report back when I get the vehicle back. No loaner was offered and I didn't ask for one.

- Frank L., Morgan Hill, CA, US

problem #3

Sep 022015

Fusion Hybrid SE 2.5L

  • Automatic transmission
  • 67,345 miles

I purchased the car from a Houston, Tx dealer in August 2015 and immediately had problem of dying car while traveling down the highway. Once my battery ran out the car would stall. Restarting the engine seemed to reset it. I was told of a safety customer satisfaction issue that Ford had agreed to regarding this problem. However, the Dealer claimed my car was not affected by that issue since my car was a hybrid. They replaced the throttle body with the same throttle body replacement used on the 2.5 engines(which I have) yet it wasn't covered by this extended warranty. I have several claims into Ford (CAS 7578227) but have heard nothing. I believe hybrids should be included in the extended warranty for these throttle body's.

Update from Jun 9, 2016: The NHTSA Investigation # is PE13003. Ford agreed to extend the warranty to 10 years 150,000 miles and replace upon failure all throttle body's on 2010 Ford Fusions. Hybrids need to be included as they use the same engine and throttle body.

- Randall C., Montgomery, TX, US

problem #2

Dec 282014

Fusion Hybrid SEL

  • Automatic transmission
  • 24,700 miles

Driving on hwy and wrench came on. This happened before but the car seemed to reset itself, and I was told there were no issues. This time the red warning light and "pull over immediately" came on. The car immediately lost acceleration, was barely able to get to shoulder. I restarted the car and this occurred several more times. I got off the hwy & took side roads, over 50 mph the problem happened again. At lower speeds I was able to get home without incident.

THIS IS DANGEROUS! It happens at high rates of speed - hwy, and you lose acceleration in traffic going 70 mph or more. Looks like I am not the only person who is experiencing this problem. Car is going to the dealer today.

- K B., Bradenton, FL, US

problem #1

Dec 102013

Fusion Hybrid

  • CVT transmission
  • 60,000 miles

Tow to dealership was covered under insurance.

Lost day at work and five days of a loaner cost.

Repair lead to an additional repair that I also had to cover as the dealership had no record of having removed my wheels in order to replace the wiring harness, and miss-replacement caused the bearings to wear and be destroyed within 2-3 weeks later.

See next of 4 complaints.

- Gary H., Orlando, FL, US

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