Ford Fusion fuel system problems, 2016–2020
204 of the 4,117 complaints owners filed with NHTSA about the Ford Fusion 2016–2020 name the fuel system (NHTSA’s “Fuel/Propulsion System” heading — fuel tanks, lines, pumps and injection — and on an EV, the propulsion battery and motors). The loudest years: 2016 (92), 2017 (42), 2018 (31). Filed under the same heading across these years: 2 manufacturer bulletins, 1 recall campaign. Every figure is a linked federal record; none is a failure rate, none a repair cost, and none a verdict on one car.
Ford Fusion fuel system problems by model year
Source: NHTSA complaints, recalls, investigations and manufacturer communicationsOne row per model year on file, newest first. A year marked in depth has its own page: the complaints, the owners’ words and every document under this heading for that year.
| Model year | Complaints naming the fuel system | Share of the year’s | Typically at | On file under the heading | |
|---|---|---|---|---|---|
| 2020 | 13 | 6% | — | — | the year → |
| 2019 | 26 | 6% | — | — | the year → |
| 2018 | 31 | 6% | — | — | the year → |
| 2017 | 42 | 4% | 52k | — | the year → |
| 2016 in depth | 92 | 5% | 62k | 1 recall | the record → |
Two things the counts carry that are not the car: how many of each year were sold, and how long each has been on the road — an older year out-counts a newer one before anything is wrong with it. The share column is the honest comparison across years: what part of that year’s complaints named the fuel system. Nothing here is a rate.
When the fuel system complaints were filed, and at what mileage
Source: NHTSA complaint databaseFiled per calendar year, every model year together: 2016: 12 · 2017: 4 · 2018: 16 · 2019: 16 · 2020: 25 · 2021: 7 · 2022: 14 · 2023: 23 · 2024: 40 · 2025: 30 · 2026: 17
Across the model years, half of the 96 owners who gave an odometer reading reported the fuel system problem between 28,000 and 81,000 miles. A median of reports, not the life of a part.
In owners’ own words
Source: NHTSA complaint databaseFiled with NHTSA by the people who own these cars, about the fuel system, from the model years with the most to say. Quoted as written, with anything identifying removed; unverified reports — what was said, not a finding that it was true.
The car will stall when coming to a stop and only at low speeds when coming to a stop. Never while driving the fuel filler flapper will vibrate making a what sounds like a growl. Try to restart it will run fruff and die.
We've been experiencing the swishing movement of the the gas in the gas tank when braking, going over a rugged surface & going over speed bumps or potholes. Some times there is a strong smell of gas from inside the car to the point where we have to put the windows down.
NHTSA COMPLAINT - 2017 Ford Fusion Energi Titanium (VIN: REDACTED) - (Collision) Q1: FAILED COMPONENT Battery Energy Control Module (BECM) and hybrid battery cell balancing circuits failed post-collision. Per Ford Recall 23V-440, Current Interrupt Device causes excess voltage, fire risk, toxic gas exposure.
The contact owns a 2017 Ford Fusion. The contact stated that the check engine warning light was illuminated. The message to clean around the gas cap was displayed. The contact stated while driving 30 MPH, the vehicle made an abnormally loud sound and was vibrating. The contact pulled over to the side of the road.
The contact owns a 2018 Ford Fusion. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic and was diagnosed with a failed EVAP purge system. The contact was informed that the EVAP purge system needed to be replaced.
What is on file about the fuel system, across the years
Source: NHTSA recalls, investigations and manufacturer communicationsRecall campaign filed under this heading, any model year
- 15V618000 HighOct 1, 2015 · 658 vehicles
- Ford Motor Company (Ford) is recalling certain model year 2016 Ford Fusion vehicles manufactured September 3, 2015, to September 13, 2015, and 2016 Lincoln MKZ vehicles manufactured September 3, 2015, to September 12, 2015. The affected vehicles have a fuel tank that may have insufficent wall thickness. As a result, the fuel tanks may crack in the event of a crash and thus the vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 301, "Fuel System Integrity."
2 manufacturer bulletins filed under this heading, any model year
- Jan 16, 2026
- Some 2016-2017 Edge/MKX, 2017 Continental/Fusion/MKZ vehicles equipped with a 2.7L or 3.0L EcoBoost engine and built on 1-Apr-2016 and through 1-Jan-2017 may exhibit white or blue smoke from the exhaust, rough idle in neutral or park at normal operating temperature or after a hot restart. The vehicle may also exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DT
- Aug 27, 2025
- This article supersedes TSB 24-2345 to update the Service Procedure. Some of the vehicles listed in the Model statement above may exhibit an oil leak from the engine oil pan RTV seal. This may be due to a lack of RTV adhesion.
Every one filed under the heading is listed. Quote the document number at a service desk — it is a diagnosis the maker has already written down.
Other systems with a record on the Ford Fusion
Source: the same files- electrical problems
- transmission and drivetrain problems
- engine problems
- brake problems
- steering problems
- backup camera and parking sensor problems
Every system, every model year: Ford Fusion problems by year →
Common questions
Source: NHTSA complaint database, recalls and manufacturer communicationsWhich Ford Fusion years have the most fuel system complaints?
2016, 92; 2017, 42; 2018, 31. Raw counts, and an older year has had longer to collect them; by share of each year's own complaints the loudest is the 2020 (6%).
Is there a recall for the fuel system on the Ford Fusion?
Yes — one campaign is filed under this heading across these model years: 15V618000 (2016). A recall is matched by VIN, and applies to specific years; check yours at nhtsa.gov/recalls.
When do fuel system problems show up on the Ford Fusion?
Owners who gave an odometer reading reported it at a median of 65,000 miles across the model years; half of them between 28,000 and 81,000. That is when reports cluster, not the life of a part.
What does NHTSA's "Fuel/Propulsion System" heading cover?
Fuel tanks, lines, pumps and injection — and on an EV, the propulsion battery and motors. Owners choose the heading when they file, so it says which area of the vehicle the complaint is about, not which part failed.