2011 Ford Fusion Problems

The driver's side air bag inflator may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling. An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.

Fix: Ford will notify owners, and dealers will replace the driver-side airbag inflator or module with an alternate one, free of charge.

The parts include certain driver-side air bag inflators and/or modules, designed to fit 2005-2014 Ford Mustang and Mustang GT500. It also includes certain passenger-side air bag inflators and/or modules designed to fit 2005-2014 Ford Mustang, 2010-2012 Lincoln MKZ, 2010-2012 Ford Fusion, 2010-2011 Mercury Milan, 2007-2011 Ford Ranger, and 2007-2010 Lincoln MKX vehicles. Please see Ford's recall report for the specific part numbers. These parts may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling. In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.

Fix: Ford will notify dealers that purchased the affected parts, and dealers will provide replacement parts to purchasers, free of charge.

A replacement frontal air bag inflator can degrade over time from humidity and temperature changes, so it may explode when the air bag deploys in a crash. Sharp metal fragments could then strike the driver or passengers and cause serious injury or death.

Fix: Dealers will inspect the driver and passenger air bag modules and replace the module or inflator if needed, free of charge.

S. Virgin Islands or "Zone A." Additionally, Ford is recalling certain 2011 Ford Ranger and Mercury Milan vehicles, 2011-2012 Ford Fusion and Lincoln Zephyr/MKZ vehicles and 2011-2014 Ford Mustang vehicles sold, or ever registered, in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." Ford is also recalling certain 2010 Ford Edge and Lincoln MKX vehicles, 2010-2011 Ford Ranger and Mercury Milan vehicles, 2010-2012 Ford Fusion and Lincoln Zephyr/MKZ vehicles, and 2010-2014 Ford Mustang vehicles sold, or ever registered, in the states of AK, CO, CT, ID, IA, ME, MA, MI, MN, MT, NH, NY, ND, OR, RI, SD, UT, VT, WA, WI, and WY or "Zone C." These vehicles are equipped with air bag inflators assembled as part of the passenger frontal air bag modules, used as original equipment or replacement equipment (such as after a vehicle crash necessitating replacement of the original air bags), that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling. An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.

Fix: Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge.

S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Ford is recalling certain model year 2007-2008 Ford Ranger, Edge and Lincoln MKX vehicles, 2006-2008 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2005-2006 Ford GT vehicles and 2005-2008 Ford Mustang vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia, or "Zone B." Any vehicle not included in "Zone A", or "Zone B" is not included in the safety recall. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling. An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.

Fix: Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge.

The affected vehicles have fuel vapor canisters whose purge valves may not operate properly resulting in abnormal pressure changes in the fuel tank. The pressure changes may cause the tank to crack and leak fuel. A fuel leak in the presence of an ignition source increases the risk of a fire.

Fix: Ford will notify owners, and dealers will update the vehicle powertrain control modules and inspect the vehicle for any diagnostic trouble codes (DTCs) for this issue and perform a leak test on the Canister Purge Valve (CPV). The fuel tank will be inspected for cracks.

A steering motor sensor fault can cause the electric power steering assist to shut down. Without assist, the wheel becomes much harder to turn at low speeds, which raises the risk of a crash.

Fix: The dealer will check the power steering control module for fault codes and, if any loss-of-assist codes are found, replace the steering gear free of charge.

The affected floor mats may move and possibly interfere with the accelerator pedal. The floor mat could shift such that it could interfere with the accelerator pedal, preventing its return to an idle position, which could result in unintended vehicle speeds, increasing the risk of a crash.

Fix: Ford will notify owners, and dealers will install new replacement mats, free of charge. NOTE: Vehicles built after October 31, 2010, while potentially equipped with the same floor mats, are equipped with a Brake Over Accelerator (BOA) feature that prevents simultaneous accelerator and brake application, allowing the vehicle to be safely stopped by pressing firmly and steadily on the brake pedal.

The wheel studs may fracture, potentially causing a wheel to separate. While driving, multiple stud fractures could occur at the wheel location, and the operator may experience vehicle vibration and/or wheel separation, increasing the risk of a crash.

Fix: Ford will notify owners, and dealers will inspect the rear brake disc surface for flatness and replace the discs as necessary. Additionally, the wheel lug nuts will be replaced on all four wheels.