2020 FORD FUSION Engine Problems

In early October 2025, the vehicle was taken to an independent dealership service department for a routine oil change. Several weeks later, the vehicle appeared to be leaking fluid and began experiencing loud knocking/clacking noises, significant vibration, and drivability concerns, especially during acceleration. On October 10, 2025, while parked at a family member’s residence, the vehicle would not start. Due to safety concerns, the servicing dealership arranged for the vehicle to be towed for inspection. Technicians found a split transmission hose causing transmission fluid loss, which was repaired; however, the abnormal noises, vibration, and drivability issues persisted. Further inspection identified loud popping/clacking noises from the bell housing area. The technician physically inspected the flex plate and documented that the flex plate was cracked. The dealership advised that a cracked flex plate can worsen, cause severe vibration, damage related components, and lead to drivability issues or potential loss of propulsion. Because of the nature of the failure and symptoms, the vehicle was removed from regular use due to safety concerns. The vehicle was later taken to a manufacturer-authorized Ford dealership, which confirmed flex plate failure but stated the vehicle did not qualify for a customer satisfaction program due to engine variant. A goodwill/financial assistance request was submitted and denied. Technician diagnostic documentation from the manufacturer-authorized dealership was requested but not provided prior to filing this complaint. No crash or injury occurred; however, the failure created a risk of sudden inability to propel the vehicle while driving, including at highway speeds. The vehicle remains unrepaired and parked due to cost and safety concerns.

My Ford started making a loud noise whenever the accelerator wasn't being pressed, after taking it to the mechanic, he said it is the cracked flex plate. After some light research, it was aparent that this is an issue that Ford's cars have, and ford has tried to make it better by offering free fixes. I contacted the local ford dealer and since the car has 90,000 miles, it would have been covered. However, since it doesn't have a clean title, I was declined this service free of charge. I don't agree with this decision since I've been driving this car for over a year since it was purchased off IAA auction, and this issue was made clear only yesterday, but this issue is prevalent in cars like mine.The damage to my car specifically was to the back, and only affected the rear bumper and trunk. Therefore I don't think it is fair that I was declined the serve even though Ford has made it clear it is there manufacturing mistake and they are willing to fix it, just not with cars with my type of title. I was hoping to send in this incident so that this issue becomes a national recall, and more people can get their cars rightfully fixed and aware of this serious issue that can make the car completely unusable before it gets too late. I wasn't aware this was a common issue when purchasing this car, so a recall would protect more people since it will become mandatory information for owners to be aware of this issue. Thank you!

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. The error message had appeared the day before, but the vehicle would still shift and the error message went away after a few seconds. I was unable to recover the original bushing as it was missing when the vehicle was inspected after the error message. Luckily the error did not happen while driving and instead was noticed while the car was in park. The vehicle has not been inspected by anyone other than myself, and I was able to buy a replacement bushing from a local dealership to replace the missing bushing.

My 2020 Ford Fusion has experienced three separate flexplate failures, as well as transmission issues following the most recent repair. Failure #1: Occurred before I owned the vehicle (confirmed later in the vehicle’s history). The flexplate was replaced by a prior owner in 2022. Failure #2: [8/2023] – While I owned the vehicle, a loud rattling noise came from the engine area. My vehicle was towed to Foothill Ford, where it was purchased, and they replaced the flexplate. No power loss occurred. Failure #3: [5/2025] – The same rattling sound returned. I drove it to Green Ford, who confirmed the flexplate needed to be replaced, and they replaced it. No power loss occurred, but the noise was severe. After the third flexplate replacement, the transmission began slipping during acceleration. This issue did not exist before the repair, and Green Ford had told me the transmission was fine before they replaced the flexplate. Safety concern: Repeated flexplate failures and subsequent transmission slipping could cause loss of propulsion or difficulty maintaining speed if the problem occurs at highway speeds or in heavy traffic, creating a potential crash risk. I did lose power on the highway, but was able to pull safely off the shoulder and called a tow truck.

The check engine light came on. The car was regularly losing coolant but none was leaking out. I topped it off but the coolant level lowered again. My mechanic suspects it is a problem with the Ecoboost engine where the coolant leaks into the cylinders. I know there is currently a class action lawsuit against for for Fusions from 2013-2019 addressing this problem.

The contact owns a 2020 Ford Fusion. The contact stated while driving 25 MPH, the vehicle failed to accelerate as intended while depressing the accelerator pedal. The check engine warning light was illuminated. The contact stated there was an abnormal sound coming from the engine. The vehicle as taken to the dealer; however, no cause for the failure was found. The cam shaft sensor was replaced; however, the failure persisted. The contact stated that on another occasion, while driving 8 MPH, the engine seized. The message "See Manual" was displayed. The vehicle was taken to an independent mechanic but was not diagnosed or repaired. The vehicle was taken to several dealers and independent mechanics. The contact was recently informed that the engine needed to be replaced. The vehicle was not repaired due to the cost. The manufacturer was not notified of the failure. The failure mileage was approximately 152,000.

Mileage: 152,000

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. The vehicle as taken to an independent mechanic and was diagnosed with engine block failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and a complaint was filed. The failure mileage was approximately 71,000.

Mileage: 71,000

The contact owns a 2020 Ford Fusion. The contact stated that while driving at various speeds or while the vehicle was idling, there was an abnormal clunking sound coming from the vehicle. There were no warning lights illuminated. The vehicle was taken to the local dealer where it was diagnosed and determined that the flex plate had fractured. The vehicle was repaired; however, the failure recurred. The manufacturer was not contacted. The failure mileage was approximately 25,000.

Mileage: 25,000

I purchased a used 2020 Ford Fusion from Carmax n 2023 with about 56,800 miles. A week later was involved in a nor side impact accident on the back end driver side, insurance paid for a dinted door and there was no other issues with the vehicle according to SONS ford. In 2024 I was on the highway (going about 80 mph) when my engine light came on, no more than 3 minutes later all the lights in my car flickered and i lost power to my entire car almost causing me my life, roadside assistance and a mechanic who had thankfully pulled over explained that my alternator completely shredded my belt. I paid for both my alternator and belt to be replaced But most recently (2025) I continued to whirring and knocking noises for 3 days (no warning lights) , I took it to firestone who stated I needed a motor repair so I got it towed to the dealership. A Ford certified mechanic stated my Flex Plate was cracked and it begin breaking off and how I needed a new starter as well leaving the car inoperable. They confirmed this was very uncommon due to the car age and the miles on it (80,000 mi) I’ve also reviewed the complaints on NHTSA and it looks like a lot of 2020 ford fusions are having these issues but yet no recall.

My car is at 47,000 miles and i started To hear a loud noise . Turns out ford says it’s the Flywheel, transmission pump, and torque converter per ford technician who completed my inspection . No warning lights came on nor was there any alerts the ford app. My 2020 Ford Fusion with approximately 48,000 miles experienced a cracked flexplate. This caused severe engine vibration, knocking sounds, and ultimately loss of power while driving. A cracked flexplate can lead to sudden engine stalling or failure to accelerate, especially at highway speeds or during intersections. This puts the driver and passengers at serious risk of a crash due to unexpected loss of power or control. This issue happened without warning and is a known problem in vehicles with the 2.0L EcoBoost engine and 6F35 transmission. Ford is aware of the issue (Customer Satisfaction Program 22N12), but my VIN was not included, even though the symptoms and components match the defect. I am reporting this because it jeopardized my safety and others on the road, and I believe more vehicles should be covered under the existing CSP or a recall.

My 2020 Ford Fusion has had multiple transmission failures and has now had a third transmission installed. The newest issue with with the engine design that Ford is aware of but is not covered by extended warranty. The engine block is cracked due overheating caused by coolant intrustion and flexplate problems. Each time these incidents were identified and examined by Ricart Ford in Columbus, OH. The car was also purchased by the same dealer in January of 2024. The check engine light along with the temperature light were triggured by the engine issue on [XXX] I immediately contacted Protective(My warranty company) and requested that the car be transported to Ricart. I also contacted the service deparment at Ricart and explained the issue. There was plenty of coolant in the resevoir but the coolant leaked into the cylinders and caused the car to overheat. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6

As I was driving last week i suddenly lost engine power and broke down. Had it towed and ford says there’s zero compression in 2 cylinders. It’s a 1.5 ecoboost which I’ve read has issues. 96,448 miles

The contact owns a 2020 Ford Fusion. The contact stated that after starting the vehicle there was an abnormally loud knocking sound coming from the engine compartment. The vehicle was taken to the local dealer who diagnosed that the flex plate was cracked and needed to be replaced along with the torque converter, the transmission fluid pump, and seals. The vehicle was repaired. The manufacturer was notified of the failure and informed the contact that the vehicle was no longer eligible for a Customer Satisfaction Campaign related to the failure. The failure mileage was 122,000.

Mileage: 122,000

Component or system that failed: Flex plate, engine electrical system, and alternator (possible related failures). The issue has been diagnosed by a licensed mechanic and is available for inspection upon request. Incident Description: On April 15, 2025, while driving my 2020 Ford Fusion SE 1.5L Turbo, the vehicle suddenly experienced a total power failure. The check engine light began flashing, and the battery light blinked rapidly. Within seconds, the engine shut down completely while I was mid-drive in traffic, leaving me stuck and unable to move for over 20 seconds. This was a terrifying and dangerous situation that nearly put my life at risk. I was eventually able to restart the vehicle, but it began shaking and rumbling violently — worse than ever before. This issue was never present before my car was involved in two separate collisions, where both other drivers were found 100% at fault. The vehicle was repaired at Fix Auto Santee (a USAA-assigned body shop), but they failed to inspect internal components. A licensed mechanic at J&L Auto Care later confirmed a broken flex plate and advised it was unsafe to drive. This problem has not been addressed or fixed by the responsible insurers (USAA and AAA) or the body shop. It has progressively worsened and now created a life-threatening situation. Warning lamps or symptoms before failure: A rattling and vibrating noise began immediately after I picked up the car from the body shop in March 2025. No lights were initially present. The electrical and engine lights only appeared on April 15 when the engine shut down mid-drive. Inspected by: •Independent service center (J&L Auto Care, diagnosed flex plate failure) •USAA and AAA were informed but refused to cover or further inspect the damage •Fix Auto Santee heard the issue but refused to inspect, citing body-only service Problem available for inspection: Yes — vehicle is currently undrivable and available for full inspection.

I have had 2 transmissions within the last year, making this the third Transmission on my vehicle. I had to have another common issue with the car replaced, which is a purge valve. My ABS light goes off often causing difficulty to steer the car and warning lights are activated showing that the safety features are not available. Lastly, there is a crack in the engine block caused by coolant in the spark plug due to overheating. This engine issue is one with the engines that Ford is aware of but I do NOT see a recall. The engine is blown due to this design and the warranties do NOT cover it. Case number [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2020 Ford Fusion. The contact stated that while driving approximately 35 MPH, the message "Engine Coolant Over-Temperature" was displayed, and the temperature gauge warning light illuminated. The contact pulled over to the side of the road and turned off the vehicle. The vehicle was restarted after 20 minutes. The vehicle was taken to the residence. The vehicle was towed to a dealer, where it was diagnosed and determined that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 132,000.

Mileage: 132,000

The contact owns a 2020 Ford Fusion. The contact stated that after starting the vehicle, while the vehicle was idling, there was an abnormal knocking sound coming from the engine. There was no warning light illuminated. The vehicle was taken to two independent mechanics, and unknown repairs were performed on the vehicle; however, the failure persisted. The contact took the vehicle to a dealer, where a diagnostic test was performed. The diagnostic test determined that the flex plate was cracked and needed to be replaced. The manufacturer was notified of the failure but offered no assistance. The contact was referred to the NHTSA Hotline to report the failure. The vehicle was not repaired. The failure mileage was approximately 117,000.

Mileage: 117,000

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. Vehicle has approximately 62,000 miles, just 2,000 miles out of warranty. Ford Customer Satisfaction Program 22N12 address the issue with an extended warranty for certain model variants (Vehicles Equipped with a 2.0L EcoBoost Engine and 6F35 Transmission). My vehicle has suffered the same failure but has a 1.5L engine so has been excluded.

Hard shifting when accelerating/decerating, jerking of the car due to transmission issues (80k miles), ABS/Braking issues due to engine components not being in sync, etc

The contact's husband owns a 2020 Ford Fusion. The contact stated while driving at various speeds, there was an abnormal rumbling sound coming from the engine. There was no warning light illuminated. The vehicle was taken to a dealer where a diagnostic test was performed. The mechanic discovered a failure with the flex plate. The contact was initially informed that the vehicle was covered under warranty; however, the contact was later informed that the engine repair was not covered under warranty. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline to report the failure. The vehicle remained with the dealer unrepaired. The failure mileage was approximately 70,000.

Mileage: 70,000

The alternator was producing too many volts, which would short circuit the battery and electrical components in the car. This would cause the car to lose power and not be able to accelerate. My car would randomly lose power on the highway, with no warning, resulting in my car suddenly slowing down. This was dangerous for the cars around me who are going 60+ and then my car quickly drops to 40 or less mph. In addition, to solve the issue I would have to pull off onto a shoulder to shut the car off and back on. This issue started around 3-4 yrs ago and has gotten worse as time passed. The problem was identified and resolved by Firestone when they ran a diagnostic. No check engine light was on in the car to alert me of any issues. I replaced both parts on the car.

The contact owns a 2020 Ford Fusion. The contact stated that the fuel door would randomly disconnect from the vehicle. While idling at a stop light, the vehicle shut off. The contact stated that while restarting the vehicle the vehicle jerked and hesitated while shifting gear before accelerating. The vehicle was taken to the dealer who was unable to determine the cause of the failure because there was no warning light illuminated. The fuel door had been replaced; however, the vehicle still experienced the failure with the START/STOP function. The contact stated that the failure became a persistent failure. The contact stated that approximately 6 to 8 months after the first failure, while driving approximately 35-45 MPH, the vehicle stalled. The contact used the App to restart the vehicle. The check engine warning light was illuminated. The vehicle was returned to the dealer however, the cause of the failure could not be determined. The dealer rebuilt the transmission, clutch, and axle; however, the failure persisted after the repairs. The vehicle was returned to the dealer who was unable to determine the cause of the failure. The vehicle had been taken to the dealer 22 times. The manufacturer was not made aware of the failure. The approximate failure mileage was 25,000.

Mileage: 25,000

The contact owns a 2020 Ford Fusion. The contact stated that while operating the vehicle, there was a ticking and knocking sound coming from the engine compartment. The vehicle was taken to the local dealer. The cause of the issue was not yet determined. The manufacturer was not contacted. The failure mileage was 79,000.

Mileage: 79,000

There was a recall on 2020 Ford Fusions in 2022 on flex plate. My car miles at 90,000 and I started to hear the ticking noise. I did my research and I seen that it has the same noise that my car is making now. I called the dealership and the dealership said that I had no active recalls on my car and that the recall was specific to certain cars. Even though my car wasn’t apart of the specific VIN. I had a mechanic check it out and it was the flex plate. I’m still having issues with my flex plate but they want me to come out of pocket , I never had a engine light or anything come on I just started hearing this loud noise and it progressively has gotten worse.

THE COMPONENT THAT HAS FAILED IS THE FLEXPLATE, TRANSMISSION FLUID PUMP, AND TORQUE CONVERTER. IT WAS EVALUATED BY FORD AND CONFIRMED THAT IT IS THE SAME ISSUE AS A PREVIOUS CSP THAT FORD ISSUED IN 2022/23, BUT I WAS NEVER NOTIFIED OF THE ISSUE. NO LIGHTS OR WARNINGS PRIOR TO THE ISSUE. IT BECAME NOTICEABLE ON OR AROUND 9/20/24.

The contact owns a 2020 Ford Fusion. The contact stated while driving 30 MPH, the vehicle hesitated and stalled while depressing the accelerator pedal. The check engine warning light was illuminated. The dealer was contacted and notified of the failure. The vehicle was diagnosed with an internal engine failure. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 65,000.

Mileage: 65,000

The contact owns a 2020 Ford Fusion. The contact stated while attempting to start the vehicle, smoke and an abnormal odor was coming from the rear of the vehicle. The check engine warning light was illuminated. The vehicle was driven to the dealer. The dealer determined that the failure was caused by a purge control valve failure. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 40,000.

Mileage: 40,000

Flex plate is cracked , confirmed by bore scope dealership is quoting 14 business days to diagnose. It is known issue with this make, model, and year and CSP was issued for dealerships to fix but only select VIN numbers. This car is at 91000 miles and meets all criteria for the CSP 22N12. The car makes an ungodly rattling sound and if it fails could be very dangerous

The contact owns a 2020 Ford Fusion. The contact stated that while driving at various speeds, there was a rattling sound coming from the engine compartment. The contact stated that the sound was also noticed while idling or with the air condition activated. The check engine warning light was illuminated. The vehicle was taken to a local dealer where it was diagnosed and determined that the flex plate needed to be replaced. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 84,994.

Mileage: 84,994

The engine is “eating” the coolant causing the vehicle to overheat and break down.

The contact owns a 2020 Ford Fusion. The contact stated that while starting the vehicle, there was a rattling noise coming from the front end near the driver’s side close to the transmission. The vehicle would start moments after the failure had occurred. The rattling was more pronounced while the A/C system was running. The contact stated that while depressing the accelerator pedal, the rattling sound was noticeable. Additionally, while driving at various speeds, the transmission felt as though it was slipping while changing gear. The contact stated that while inspecting the engine, underneath the hood was hotter than normal. The check engine warning light was illuminated. The vehicle had been taken to the dealer where it was diagnosed that the transmission flex plate had failed. The failure was linked to NHTSA Campaign Number: 10218899 (Power Train). The vehicle had not been repaired. The manufacturer was made aware of the failure, and it was confirmed that the VIN was not under recall. The contact was referred to the NHTSA Hotline to file a complaint. The failure mileage was 117,000.

Mileage: 117,000

Cracked flexplate

Intrusion into cylinder 2.

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. The problem is they installed crappy plates that crack between 60k-90k miles. As others have reported the Luckily for them It was at an intersection and could pull over to the side of the road but imagine if this happens to you while on the freeway!

At first the check engine light was on and the car would not start. The dash would display all the lights and at one point it turned off while driving luckily I was going 20-30mph. Took it to the dealership and they said an Intake Valve had to be replaced and it was covered by the warranty. Next the engine light was on and a MAP censor had to be replaced which wasn’t covered. Once again the engine light and service light came on and the code is saying the same censor needs to be replaced. Each time it has effected how the car drives and is dangerous especially on the interstate because it will not go over 20mph. When the car is in reverse it will shake and turn off displaying auto start stop issue and place the car in park. It will then turn off. It is hit or miss on when the check engine light and maintenance light will come on and each time the symptoms are the same. No one has provided a solution. This has been on going for almost a year.

The contact owns a 2020 Ford Fusion. The contact stated while driving at an undisclosed speed, the vehicle was making an abnormally loud sound. The vehicle then failed to shift into drive or reverse. There were no warning lights illuminated. The vehicle was towed to the local dealer to be diagnosed. The contact was informed that the cam shaft thrust plate was damaged and there was damage to the crank shaft. The manufacturer was contacted and referred the contact to the NHTSA Hotline. The failure mileage was approximately 99,964.

Mileage: 99,964

The car seems to lose power sometimes when you are going down the road. My engine light came on but it brings up a fuel cap code, and a emission control sensor. The extended warranty covered the emissions control purge valve. This started around 70,000 miles.

Constantly with this specific vehicle, especially with the lane assist. The vehicle continuously jerks either left or right even within the green parameters of the lane, especially when doing a slight turn on the highway. When it is raining the vehicle smart as go offline an cannot read the lane or the vehicle in front of it. When I first purchased the vehicle after driving for less than a year I had to take the vehicle in because the engine was warped. Constantly when I’m the vehicle the Apple car play system would either freeze or the screen would go black.

There is Exhaust smell of rotten eggs that enter the cabin while driving and it happens almost every drive. I have brought the car to the dealer where they ran tests but found no problems. As soon as I got the car back it started producing the rotten egg smell again.