NHTSA Complaint #11488663 — 2015 FORD FUSION

A flaw in design allows coolant intrusion into the cylinders ruining the engine and requiring engine replacement. TSBs have been issued on this problem which is caused by a flaw in the design. The car drove fine Monday morning, 9/19/2022 On Monday evening, driving 80 mph, (which is the speed limit on the 130 Toll Road), the car suddenly started shaking, slowed and did not want to accelerate and the check engine light started flashing. The car was checked with OBD reader, error code P0302, a misfire in cylinder 2. The next morning, 9/20/2022, after confirming with Ford service that it would be ok drive, drove 5.5 miles to dealership, with the car shaking, vibrating & check engine light flashing. On 9/22/2022 we were told the engine needed to be replaced at a cost of about $11,000. After researching online, I found there is a known design flaw on the Ecoboost engines that allows the intrusion of coolant into the cylinder and the only repair is engine replacement. Ford has been aware of the flaw in design on the Ecoboost engines for years but continued to manufacture and sell them putting peoples lives in danger by selling a car that can suddenly lose power, vibrate violently and possibly catch on fire if it overheats. There is a Customer Satisfaction Program 21N21 covering the short block on 2017-2019 Ford Fusion Ecoboost cars but nothing on prior years. Per a Ford Customer Experience Specialist I was informed that financial assistance on my car ended at 7 years or 150,000 miles; any assistance they could have offered ended on 9/14/2022; 6 days prior to the incident. I was informed that how Ford determines financial assistance is proprietary and no further explanation could be given.. I understand the car is 8 years old; however, a well-built car with low mileage (53,590) should not need a new engine. What happened to Ford “Built to Last?” Ford needs to stand behind their products and do the right thing by covering the costs of repair due to a design flaw.