2016 Ford Fusion power train problems

“The flexplate has failed twice since a dealer-performed transmission replacement in June 2024, once in August 2025 and again in August 2026. A flexplate failure causes sudden loss of the ability to move the vehicle under power, which is a safety hazard, particularly while merging, accelerating onto a highway, or in traffic. A Ford service bulletin covering the closely related Escape with the same engine and transaxle architecture documents that flexplate cracking is linked to engine-to-transaxle alignment issues that arise whenever the engine and transmission are separated, which is exactly the service performed during a transmission replacement. This report is filed because the recurrence of an identical failure mode, on a known-affected platform, without resolution by the servicing dealer, appears to reflect an unresolved and potentially widespread mechanical defect rather than an isolated incident."”

“The engine experienced a sudden failure that caused the vehicle to become completely inoperable. Prior to the failure, the vehicle exhibited intermittent hesitation, rough idling, and loss of power during acceleration. These symptoms began several weeks before the complete failure. No warning lamps were illuminated at first, but shortly before the breakdown, the vehicle displayed a check engine light and a “Service Engine Soon” message. While driving, the vehicle abruptly lost power and became unsafe to operate. I was forced to pull over immediately, which created a safety risk to myself and other drivers due to the sudden deceleration and inability to maintain speed in traffic. The vehicle would not restart afterward. A repair facility has confirmed that the engine has suffered a major internal failure and requires replacement. The estimated cost of repair starts upwards of $5,000. The vehicle is currently non‑drivable and remains available for inspection. The issue has been reproduced and confirmed by an independent service center. The vehicle has not yet been inspected by the manufacturer, police, or insurance representatives. However, I have found multiple…”

“severe coolant intrusion issue where coolant leaks into the cylinders, causing rough running, overheating, and potential engine failure. Very unsafe especially due to the fact the their were recalls on the 2017-2019 but not for 2016 models and ford refuses to replace the engine.ford reproduced a better block however my 2016 isn't covered. There signs of rough idling and a engine code for a failed coil . Replaced all coils and spark plugs just for the car to still ride rough with no warning signs. Ford knows themselves that there was a flaw in the making the recall for the 2017-2019(21N12) . This is a major issue considering several reviews or reddit consumers have encountered the exact issue at 100k miles and less. Even when I took my car to bill estes they only found a missfire due to coil. Nothing specified a coolant intrusion.”

“I was driving my car one day and as I was coming down the road the car jerked and picked up speed like on its on and I had to really stop abruptly to stop the car. I thought that was strange, I didn't have any warning lights or any indication that anything was going on I just thought it was weird, then like 2 days later as was driving the car would do this random jerk but again no lights on any indication anything was wrong so I went to work car seemed fine, got on the high way to go pick up my grand kid after work and when I signaled to change lanes attempted to accelerate to pass, the car just hummed and my speed started to diminish and I immediately coasted to nearest exit because I could not accelerate more than 15 mies, I coasted to a strip mall turned the car off waited til I thought the car settled for a moment and attempted to start the car and when I put the car in gear it jerked but as I tried to accelerate it just hummed and no speed overc15 . So I left the car got it towed the next day to another shop because any ford dealerships I called to see if I could tow for diagnostic test said they had extensive waiting period like one had weeks before they…”

“I get in my 2016 Fusion to go to dinner and I can barely turn my steering wheel. I put it in park and check the power steering fluid. FULL. I tried resetting the power steering assist by starting the car and turning all the way left then right then center. Still can barely turn. Tried disconnecting the battery hoping it would be an electrical glitch. Come to find out it’s could be a steering assist motor on the steering column that’s going bad and CAN CAUSE THIS PROBLEM WHILE DRIVING! That’s insane!”

“Transmission started whining from the pump and then immediately lost power/acceleration. Electronic diagnosis found code P0733 for incorrect gear ratio for 3rd gear. Dealership recommends torque converter replacement and transmission overhaul. Fine metal debris found in transmission fluid sample. Estimate $5,500 and occurred at 110,000 miles on odometer.”