NHTSA Complaint #11683235 — 2017 FORD FUSION

The engine has suffered a complete failure due to a known defect in the 1.5L EcoBoost. This issue was already repaired once under Ford Customer Satisfaction Program 19B37/21N12 (engine short block replacement) on 10/12/2020 at Stilwell Ford, before I owned the vehicle. Less than 5 years later, the exact same defect has occurred again. Details of Failure: •Vehicle began running rough with loss of power and abnormal engine noise. •A compression test performed by my repair shop shows: Cylinder 4 = 0 psi compression, with cylinder wall scoring and oil intrusion. •Shop diagnosis: engine requires complete replacement (~$7,000 repair). •Symptoms are identical to the coolant intrusion / cylinder failure defect covered by Ford’s prior CSP. •This is the second time this defect has occurred on the same vehicle. Safety Risk: •Vehicle misfires and shakes violently, making it unsafe to drive. •Sudden loss of power and potential stalling in traffic pose a serious risk of crash. •Drivers are given no warning before engine failure occurs. Manufacturer Response: •Ford acknowledges this defect under CSP 19B37/21N12 but refuses further coverage since it was “already repaired” once. •As a second owner, I never received notice of the defect. •The fact that the failure recurred shows Ford’s repair program did not fully resolve the defect. Request: I am reporting this as a repeat safety defect. The failure has occurred again after Ford’s supposed remedy. NHTSA should investigate whether Ford’s CSP repairs adequately resolve the defect, and whether additional recalls or coverage extensions are warranted.