Wrench.Pro

2020 Ford Fusion Recalls, Issues & Maintenance

The 2020 Ford Fusion carries 3 open NHTSA recalls — most recently covering management system/energy control module (bms/becm) and software. Owners report 7 recurring issue clusters, led by “Flex plate cracking and flywheel failure.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

3 Open Recalls

Source: NHTSA

ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM)

Campaign #23V440000 · Jun 23, 2023

Issue: 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.

Risk: A damaged BECM can result in a loss of drive power or fire, increasing the risk of a crash or injury.

Fix: 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.

BACK OVER PREVENTION:SOFTWARE

Campaign #25V442000 · Jun 27, 2025

Issue: 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.

Risk: 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.

Fix: 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.

EQUIPMENT:ELECTRICAL:ENGINE BLOCK HEATER

Campaign #25V685000 · Oct 10, 2025

Issue: 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.

Risk: An electrical short circuit can increase the risk of a fire.

Fix: 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.

Recall data refreshed Sep 13, 2026.

Known issues for this vehicle

What drivers and federal regulators have officially reported about the 2020 Ford Fusion.

Reported to NHTSA

Flex plate cracking and flywheel failure

POWER TRAIN

34 NHTSA complaints · 2022-06 → 2025-10

“The flexplate in my 2020 Ford Fusion SE (1.5L EcoBoost engine) failed at just over 53,000 miles. The car began making loud knocking and rattling noises while driving, and it vibrated heavily at idle and during acceleration”
— Owner report, NHTSA ODI #11667817
“Failure of the Flywheel. It’s broken in pieces according to the dealership at greenway Ford. Did some searching on line and other people have report the same issues”
— Owner report, NHTSA ODI #11554830
“Began to hear loud rattling noise under hood. Brought to Ford dealer who determined the cause is a failed Flex Plate. Car is operable but was warned this could result in catastrophic failure of the transmission”
— Owner report, NHTSA ODI #11640622

Read all complaints on NHTSA →

Shift linkage bushing failure locks transmission in park

POWER TRAIN

16 NHTSA complaints · 2021-09 → 2026-07

“During a road trip, received an error message indicating "SHIFT SYS FAULT" after the vehicle would not shift out of park. Upon inspecting the vehicle, it was noticed that the transmission linkage cable bushing was missing”
— Owner report, NHTSA ODI #11696130
“The contact owns a 2020 Ford Fusion. The contact stated that on several occasions while driving at various speeds, the gear was shifted, and the vehicle reverted to park”
— Owner report, NHTSA ODI #11570486
“Shifter Cable broke in multiple vehicles of the same year make and model in our fleet of vehicles within a short amount of time. Car would not change gears properly”
— Owner report, NHTSA ODI #11722936

Read all complaints on NHTSA →

Lower control arm and ball joint failure

STEERING, SUSPENSION

5 NHTSA complaints · 2025-02 → 2026-04

“The front left lower control arm (driver's side) snapped off (broke) while turning a corner. There was no reason for the breakage other than turning”
— Owner report, NHTSA ODI #11734895
“While turning into a parking lot the lower control arm snapped (broke in half, approximately). The picture I sent is of a front lower control arm, however it is not a picture of the actual control arm that broke”
— Owner report, NHTSA ODI #11732267
“The ball joint broke off while driving and the car only has 44,000 miles”
— Owner report, NHTSA ODI #11673586

Read all complaints on NHTSA →

12-volt battery drain requiring repeated jump-starts

ELECTRICAL SYSTEM

8 NHTSA complaints · 2021-02 → 2025-06

“Dead battery again; this is a major concern on this particular fleet car that we have. Dealer had car towed in. I told them to check the connections”
— Owner report, NHTSA ODI #11453751
“BATTERY DRAINS VERY QUICKLY AND NEEDS TO BE JUMP-STARTED REPEATEDLY, WHICH HAS RISKS TO SAFETY AND EQUIPMENT. THIS IS A FLEET VEHICLE”
— Owner report, NHTSA ODI #11395770
“According to dealership, the 12-volt, 7 year battery passes all testing and has a "Good" (best) rating (battery is only 3 years old)”
— Owner report, NHTSA ODI #11505193

Read all complaints on NHTSA →

EcoBoost coolant intrusion into engine cylinders

ENGINE AND ENGINE COOLING

14 NHTSA complaints · 2022-03 → 2026-07

“2020 Ford Fusion 1.5L EcoBoost engine completely failed. Ford dealership diagnosed need for complete engine and turbo replacement at $13,475. Believed to be related to known EcoBoost coolant intrusion defect”
— Owner report, NHTSA ODI #11733486
“The contact owns a 2020 Ford Fusion. The contact stated that upon starting the vehicle, the contact noticed smoke coming from the engine compartment. There was no warning light illuminated”
— Owner report, NHTSA ODI #11677234
“The contact owns a 2020 Ford Fusion. The contact stated that the vehicle was started, there was a large amount of white smoke coming from the exhaust pipe, with the engine sputtering”
— Owner report, NHTSA ODI #11666086

Read all complaints on NHTSA →

Touchscreen and backup camera display lockup

ELECTRICAL SYSTEM

9 NHTSA complaints · 2020-06 → 2025-02

“THE TOUCHSCREEN DISPLAY IS NOT WORKING. IT TURNED COMPLETELY BLACK. I CAN CHANGE THE VOLUME USING THE DIALS, BUT I CANNOT CHANGE THE RADIO STATION. IT ALSO WILL NOT SHOW MY BACK UP CAMERA. I SHUT OFF MY CAR AND TURNED IT BACK ON AND IT IS STILL NOT WORKING”
— Owner report, NHTSA ODI #11359886
“Issues with Ford Sync Infotainment system have been occurring for over a year now, with the latest being on May 25th”
— Owner report, NHTSA ODI #11530920
“TL* THE CONTACT OWNS A 2020 FORD FUSION. THE CONTACT STATED THAT THE BACKUP CAMERA REMAINED ON WHILE DRIVING AT AN UNKNOWN SPEED”
— Owner report, NHTSA ODI #11328319

Read all complaints on NHTSA →

High-voltage battery pack fire (PHEV recall 23V440)

ELECTRICAL SYSTEM, STRUCTURE, FUEL/PROPULSION SYSTEM

5 NHTSA complaints · 2025-08 → 2026-03

“The incident occurred immediately after shifting the vehicle into reverse and starting to move. The engine suddenly shut down with a 'System Performance' alert, and cooling fans engaged at maximum speed”
— Owner report, NHTSA ODI #11717716
“I am reporting a life-threatening incident involving my 2020 Ford Fusion PHEV. On December 5, 2025, while my wife was driving on a public street, the vehicle suffered a sudden, complete engine failure followed by smoke and fire originating from the high-voltage battery pack”
— Owner report, NHTSA ODI #11725471
“The contact owns a 2020 Ford Fusion. The contact received notification of NHTSA Campaign Number: 23V440000 (Electrical System); however, the part to do the recall repair was not yet available”
— Owner report, NHTSA ODI #11680697

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 13, 2026. Investigation data refreshed Sep 13, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

F-150 4x4 and Bronco 4x4: replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

47 crashes 2010–2024

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

10

complaints mentioning a crash

3

complaints mentioning a fire

Reviewed known issues for this vehicle·Open recalls for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2020 Ford Fusion reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

Check another vehicle →