2020 Ford Fusion engine problems

“COMPONENT/SYSTEM: Gasoline vapor entering the occupied passenger cabin through the HVAC vents during and after rain with the A/C or heat on. Root cause unidentified, not because it cannot be found, but because Ford Motor Company has not once tested the vehicle under the condition in which the defect occurs, and has refused in writing to assign an engineer who would. Suspected fuel system / evaporative emissions / cowl-to-HVAC intake pathway. Vehicle available to NHTSA for inspection on request. SAFETY RISK: The driver and passengers breathe gasoline vapor inside a closed, moving vehicle. Fuel vapor in an occupied cabin is an inhalation hazard and an ignition hazard. The owner drives with the windows open to vent it. Ford’s own agent acknowledged in writing on 09/24/2026: “I understand that your vehicle currently has a gas odor and you do not feel safe driving it.” Ford has since returned the vehicle to the owner unrepaired four times, has never stated it is safe to drive, and has stated in writing that it is closing the case. The vehicle is on the road today with the defect present. If this condition exists on other Fusions, those owners cannot rely on Ford’s…”

“The contact's brother owns a 2020 Ford Fusion. The contact stated that while the owner was driving 35 MPH, the engine overheated and there was misfire coming from the engine. The check engine warning light illuminated, and there was fluid leaking into the engine. An independent mechanic was contacted by phone. The vehicle was taken to the independent mechanic and was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The contact was informed that the failure was a known failure with the vehicle. In addition, the contact was informed that the failure was due to the manufacturing design of the engine. The manufacturer was contacted by phone and a case was filed. The failure mileage was approximately 72,000.”

“2020 Fusion SEL with 41,000 miles. While driving at 65 mph with adaptive cruise control engaged, the vehicle suddenly jerked on two separate occasions during a three-hour drive.”

“Coolant Intrusion. Started with thick white exhaust when starting up in morning. Turned into acceleration lags, car shutting engine off when parked, and exhaust smell coming inside of car. 2014-2019 models have a recall for cracked engine block allowing cooling to leak inside, but 2020 models do not although there is an increased problem with this year and model of car.”

“COMPONENT THAT FAILED: The engine cooling fan on my 2020 Ford Fusion SEL (1.5L, non-hybrid) became inoperable and blew three fuses. With the fans not operating, the engine overheated, destroying the head gasket and engine, requiring complete replacement. Failure occurred 07/08/2026 at 49,118 miles. WARNING SYMPTOMS: The A/C began blowing warm air roughly 2 days earlier. The engine temperature lamp illuminated on 07/08/2026 — the first and only time it ever came on. No prior overheating, no coolant loss, no leaks, no other alert. I stopped driving immediately on that single warning and had the vehicle towed. SAFETY RISK: A cooling fan failure progressing to engine destruction risks overheating, loss of motive power, and stalling in traffic or at highway speed. I stopped safely; a driver getting this same lone warning on a freeway would face a serious hazard with no notice. The vehicle's protections did not prevent a low-cost part from destroying the powertrain, and the sole warning came immediately before catastrophic damage. CONFIRMED BY INDEPENDENT SERVICE CENTERS: Yes. A certified technician at a licensed independent shop found the cooling fan assembly…”

“While driving at 75mph on the freeway, my 2020 Ford Fusion suffered a sudden, catastrophic EcoBoost engine coolant failure. The vehicle instantly lost power and dropped to 35mph in active traffic, creating an extreme highway collision hazard. A mechanic has confirmed internal coolant intrusion in the engine block.”