NHTSA Complaint #11694582 — 2015 FORD FUSION

I have been having issues with the vehicle where it will stall. This even happened when I was driving on the NJ turnpike, it stalled while driving and I had to pull over (thankfully I could) to restart the vehicle. It took the dealer 3 weeks to finally figure out the issue and tracked it down to a bad BCM (Body Control Module). I researched this further and found some interesting information. A significant number of 2015 Fusion owners report similar electrical glitches, with some experiencing a complete loss of power to multiple systems, including the center console, AC, and power windows. Diagnostics have identified water intrusion and corrosion in specific connectors, such as C134 near the front bumper, as a root cause, which can be resolved by cleaning and applying electric grease. However, a failing BCM itself is a common diagnosis, especially when multiple systems fail simultaneously and no other obvious cause is found. Replacing the BCM is a known solution, but it requires programming with the vehicle's specific as-built information and PATS key programming to function correctly; a new OEM BCM typically costs around $500. The BCM must be programmed using specialized diagnostic tools like Ford IDS software or equivalent, and the process includes steps like parameter reset, CEI configuration, and battery monitor sensor reset. While some owners have successfully bypassed the BCM using an external relay for specific functions like parking lights, this is a complex workaround and not a standard fix for a failing BCM. Persistent issues, especially those that recur after resets or component replacements, often point to a defective BCM, though other factors like a faulty wiring harness or a bad ground connection should also be ruled out. Given the prevalence of these problems across 2010–2019 Ford Fusions, some owners have advocated for a recall, citing safety concerns.