Problems · by component

2012 Ford Fusion structure problems

101 owner complaints to NHTSA about the 2012 Ford Fusion cite structure, 4% of all 2,617 complaints for this model year.

Complaints
101
4% of all complaints
Crashes
13
Reported by owners
Fires
0
Reported by owners
Injuries
8
Reported by owners
01 —Owner reports

What owners say about the structure

Verbatim from NHTSA complaints, newest first
“Absolute unacceptable level of rust to the body and frame. Even with regular car washes, sitting for a year covered. It’s literally totalled and I am out of a car. It’s a 2012 with this amount of rust”
Owner complaint to NHTSAFiled Apr 24, 2025Suspension, Structure, Fuel/propulsion systemODI 11656538
“Driver door is not locking. Tried with manual key too but not successful. Tried to open door from inside but no success. Looks like door assembly or spring is faulty and designed poorly This can be a safety hazard as driver can't get out of car easily. Pls recall all Ford fusion 2012 and ask dealers to fix it. I checked few articles forums and YouTube videos and everywhere it says there might be a spring problem or some plastic issue in latch or door assembly.”
Owner complaint to NHTSAFiled Nov 23, 2024StructureODI 11627056
“The contact owns a 2012 Ford Fusion. The contact stated that while the vehicle was parked, the driver's side door failed to open using the interior door handle. The vehicle was taken to the dealer where it was diagnosed and determined that the driver’s side interior door handle needed to be replaced. The vehicle was repaired but the failure reoccurred three years later. The contact stated that on the second occasion, the driver’s and front passenger’s side windows were rolled down and the door was opened using both outside door handles. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 116,945.”
Owner complaint to NHTSAFiled Oct 3, 2024StructureODI 11617905
“This is the second time my door latch has malfunction. I'm a single parent and to keep having to come out of pocket to get the same issue fixed is a big inconvenience.The inside is broken I have to roll my window down and unlock my door from the outside just to get out of my car. This is a major safety hazard why hasn't the recalled 2012 Ford fusions been included for the door latches? I can't even lock my door and there has been numerous break-ins close by.”
Owner complaint to NHTSAFiled Apr 5, 2023StructureODI 11515653
“Front Driver Side door handle mechanism breaks and will not open the door when the lock mechanism is in the Unlocked position. To open the door from the interior, the driver must roll down the electrically-powered window and use the exterior latch to open the door. There are multiple examples of these situations and the owner’s description of repairs. Here is one example: https://youtu.be/At96DIaPyc8 This is a serious and significant safety hazard for the vehicle driver, particularly in the event of a vehicle fire or water submersion.”
Owner complaint to NHTSAFiled Dec 19, 2022StructureODI 11498075
“The contact owns a 2012 Ford Fusion. The contact stated while attempting to exit the vehicle through the front driver’s side door, the door handle fractured. The contact was able to use the remaining part of the door handle to exit the vehicle. The vehicle was not taken to the dealer to be diagnosed or repaired. The manufacturer was not contacted. The failure mileage was 31,000. The VIN was invalid.”
Owner complaint to NHTSAFiled Jul 20, 2022StructureODI 11474984

Showing 6 of 101 reports. Read every report on NHTSA.gov.

Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 2, 2026NHTSA vehicle page

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.