Edward

@ Automate - earlier this year someone posted here a Ford Tech Service Bulletin that corrects this problem by reprogramming the computer. I copied out the Bulletin, took it to my dealer (Kennedy Ford, Conshohocken, PA) and they fixed it for $130. It has been running ~ 40-41 mpg since, altho its gone down somewhat b/c of the cold weather, as it always did before.

Got an estimate for this 'rocker panel' repair at $1,700 and does not include a warranty as its likely to return. Sad, its such an otherwise good car.

Yes, on the passenger side lower frame (rocker arm?) in front of rear wheel well, the paint there is bubbling.

I'm afraid that you were overcharged if that is the only svc they performed. My dealer is Kennedy Ford, Conshohocken, PA outside Philly. They should now know how to perform this service as I left them with the Tech Bulletin.

Had the Tech Service update on Friday, took it out for a 127 mile Sunday ride along the Delaware River above New Hope to Easton, level to slightly rolling terrain, 30-45 mph, averaged 55 mpg, like when new. Before the update had been averaging ~ 31 mpg. The service rep said that he also updated other modules at the same time. Total cost $130.00.

Hi, Everyone! I had written on May 25 of having the EV problem diagnosed as a stuck thermostat which the dealer replaced, so here's an update. At first I did not notice any improvement but then it got better to the point where it drives like new (I bought my 2010 in June 2009). Just completed a 1,400 mile road trip, averaged 42 MPG over a mix of interstate, (both 70 MPH and stop-n-go), Route 1 thru Maine (30-50 MPH) and lots of back roads. Previously the EV Battery metric on left side of dash showed blue all the way up and no discharge but now its working as should. My 10 year experience with this car is that it has never delivered the city driving mileage advertised but has overdelivered on the highway mileage. Car has 90k miles, most enjoyable driver I've owned since my Saab.

Purchased my Fusion Hybrid in 2009, love the car, but this winter electric motor would not kick in. Then one rare warm day it worked perfectly, but not after the cold weather returned. The EV battery refuses to discharge, accd to dashboard. Just had it to the dealer's, diagnosis performed, said engine not getting to temperature so the engine kept running trying to get to it. Thermostat stuck open, replaced it and reprogrammed, test driven, ok. Not ok. Drove around a couple days, same problem as before, until yesterday when the temp exceeded 80 degrees and the hybrid worked as supposed to. Will have to take it back to dealer, what a waste of time. At least on my Fusion, the problem is temperature related, has to be.