NHTSA Complaint #11680924 — 2020 FORD FUSION

My 2020 Ford Fusion has experienced three separate flexplate failures, as well as transmission issues following the most recent repair. Failure #1: Occurred before I owned the vehicle (confirmed later in the vehicle’s history). The flexplate was replaced by a prior owner in 2022. Failure #2: [8/2023] – While I owned the vehicle, a loud rattling noise came from the engine area. My vehicle was towed to Foothill Ford, where it was purchased, and they replaced the flexplate. No power loss occurred. Failure #3: [5/2025] – The same rattling sound returned. I drove it to Green Ford, who confirmed the flexplate needed to be replaced, and they replaced it. No power loss occurred, but the noise was severe. After the third flexplate replacement, the transmission began slipping during acceleration. This issue did not exist before the repair, and Green Ford had told me the transmission was fine before they replaced the flexplate. Safety concern: Repeated flexplate failures and subsequent transmission slipping could cause loss of propulsion or difficulty maintaining speed if the problem occurs at highway speeds or in heavy traffic, creating a potential crash risk. I did lose power on the highway, but was able to pull safely off the shoulder and called a tow truck.