The 2019 Fusion is Ford's last-gen midsize sedan with a portfolio of troublesome EcoBoost engines—particularly the 1.5L and 2.0L turbo fours—that suffer catastrophic coolant intrusion and bearing failures far earlier than acceptable. The hybrid is more reliable, but transmission and coolant-related issues still plague the platform.
1.5L EcoBoost Coolant Intrusion into Cylinders (Cracked Head/Block)
Common · high severity
Typical onset: 40,000-80,000 mi
Symptoms: White smoke from exhaust on cold start, Coolant loss with no visible leaks, Rough idle or misfires, Milky oil or coolant in oil pan, Check engine light with misfire codes P0300-P0304
Fix: Internal coolant leak from cracked cylinder head or block requires complete engine replacement or rebuild. Ford issued TSB 19-2346 but no recall. Expect 18-24 labor hours for long-block swap including fluids, belts, and ancillaries.
Estimated cost: $5,500-8,500
2.0L EcoBoost Rod Bearing and Piston Failure
Occasional · high severity
Typical onset: 60,000-100,000 mi
Symptoms: Loud knocking from engine bay, especially under load, Metal shavings in oil during change, Oil pressure warning light, Sudden loss of power, Catastrophic engine seizure if driven after knock starts
Fix: Rod bearings wear prematurely, leading to spun bearings and grenaded pistons. Requires full engine rebuild or replacement. Root cause tied to oil dilution from direct injection and inadequate oil change intervals. 20-28 labor hours for short-block or complete rebuild.
Estimated cost: $6,000-9,500
Transmission Oil Cooler Failure (All Engines)
Common · high severity
Typical onset: 50,000-90,000 mi
Symptoms: Transmission fluid in coolant reservoir (strawberry milkshake appearance), Coolant in transmission pan, Harsh shifting or slipping, Overheating transmission, Engine overheating in severe cases
Fix: Internal transmission cooler inside radiator fails, allowing cross-contamination of fluids. Requires radiator replacement, complete transmission flush (sometimes full rebuild if contamination is severe), coolant system flush. 8-12 labor hours if caught early; 20+ hours if transmission is damaged.
Estimated cost: $1,200-2,500 early; $4,000-7,000 with transmission rebuild
Transmission Mount Failure
Common · medium severity
Typical onset: 60,000-100,000 mi
Symptoms: Clunking when shifting from Park to Drive/Reverse, Excessive vibration at idle, Visible sagging of engine/trans from underneath, Shudder during acceleration
Fix: Hydraulic transmission mount deteriorates and fails, especially on turbo engines with higher torque. Replacement requires supporting powertrain and unbolting mount. 1.5-2.5 labor hours depending on access.
Estimated cost: $350-650
Hybrid Battery Cooling System Failure (2.0L Hybrid)
Occasional · high severity
Typical onset: 80,000-120,000 mi
Symptoms: Hybrid system warning light, Reduced electric-only range, Overheating warnings, Cooling fan runs constantly, Check engine light with P1A0B or P1A15 codes
Fix: Hybrid battery cooling fan or pump fails, causing battery pack to overheat and derate. Sometimes covered under 8-year/100k hybrid component warranty if still active. Cooling pump replacement: 3-4 hours; fan assembly: 2-3 hours. Battery pack replacement if damage occurred: 6-8 hours.
Estimated cost: $800-1,500 for cooling components; $3,500-5,500 if battery damaged
Rear HVAC Blend Door Actuator Failure
Occasional · low severity
Symptoms: Clicking or tapping noise from behind dashboard, Inconsistent temperature control, Heat when AC is on or vice versa, Noise stops when HVAC is turned off
Fix: Plastic gear inside actuator strips, causing constant clicking as motor tries to adjust blend door. Requires dash disassembly for access. 2-3 labor hours.
Estimated cost: $350-550
Purge Valve and EVAP System Faults
Common · low severity
Typical onset: 50,000-90,000 mi
Symptoms: Check engine light with P0455, P0456, or P0457 codes, Rough idle after refueling, Difficulty filling gas tank (pump clicks off repeatedly), Fuel smell near filler neck
Fix: Purge valve sticks open or canister vent valve fails. Common on EcoBoost engines. Purge valve replacement: 0.5-1 hour; vent valve or canister: 1-2 hours depending on rust and access.
Estimated cost: $200-500
Owner tips
Change oil every 5,000 miles maximum on EcoBoost engines—direct injection causes fuel dilution that destroys bearings
Inspect coolant reservoir monthly on 1.5L EcoBoost for unexplained loss; catch cylinder intrusion early before hydrolocking occurs
Check transmission fluid and coolant for cross-contamination every oil change; pink or brown coolant means immediate radiator replacement needed
Hybrid models: ensure battery cooling system is functioning; listen for cooling fan operation after shutting down
Avoid extended idle times on turbo engines; oil coking in turbo and carbon buildup accelerate failure
Avoid the 1.5L and 2.0L EcoBoost gas models unless you enjoy expensive engine replacements—stick with the hybrid or walk away entirely; this platform's powertrain issues are legendary in the worst way.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
Fitment notes: Sport trim with 2.7L EcoBoost V6; AGM battery required for Auto Start-Stop system
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Every control module on the 2013-2020 Ford Fusion — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
⚠️ PATS function integrated in PCM. Key programming requires dealer tool and security access. 2018+ requires gateway unlock.
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles. The engine block heater may crack and develop a coolant leak, causing it to short circuit when the block heater is plugged in.
Consequence: An electrical short circuit can increase the risk of a fire.
Remedy: Owners are advised not to plug in their block heater until the vehicle is remedied. Dealers will replace the block heater, free of charge. Owners will also have a alternative option to replace engine block heater element with a threaded blanking plug, and remove the block heater electrical cord. Interim letters, notifying owners of the safety risk, were mailed December 3, 2025. Additional letters will be sent once the final remedy is available, anticipated September 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SA4. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on October 15, 2025.
BACK OVER PREVENTION:SOFTWARE · 25V442000
2025-06-27
Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2024 Bronco Sport, and 2022-2024 Maverick vehicles. A software error may cause the rearview camera to display a blank image, or the image may remain on the display after the backing event has ended.
Consequence: A rearview camera that displays a blank image can reduce the driver's view behind the vehicle. A rearview image that continues to be displayed after the vehicle is shifted out of reverse may distract the driver. Both of these situations can increase the risk of a crash.
Remedy: Dealers will update the rearview camera software, free of charge. Owner notification letters were mailed September 4, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S72.
ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM) · 23V440000
2023-06-23
Ford Motor Company (Ford) is recalling certain 2019-2020 Fusion PHEV vehicles. The battery energy control module (BECM) may become damaged due to excessive voltage and current flow.
Consequence: A damaged BECM can result in a loss of drive power or fire, increasing the risk of a crash or injury.
Remedy: Owners are advised not to charge their vehicles until the remedy is completed. Dealers will replace the battery and update the BECM software for free, or Ford will repurchase the vehicle. If your vehicle is currently operating normally, Ford has authorized dealers to replace the fuse block and a software update as an interim repair before the availability of remedy parts for the final repair. This repair will be free of charge (parts and labor). As an alternative remedy, Ford is offering a vehicle refund. Please see Ford's owner notification letter or contact Ford for full details. Owner notification letters were mailed May 15, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S33.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2019 Ford Fusion 2.7L V6 EcoBoost and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.