Huge Repair Bill on Fusion Hybrid ABS Light

[CAI]

I have a 2012 Fusion Hybrid with 120K miles.  Took it to dealer for oil change (the "works").  They said brake fluid was low and I let them flush it out and replace.  No issues at first but two weeks later I'm driving and I have to push brakes to the floor for the vehicle to stop.  Doesn't feels safe driving so I have the car towed back to dealer.  It takes them a whole week to figure out what is wrong.  They tell me: need to replace HCU 9e5z-20215-b ($857.03), booster 9ee5s-2005-a ($464.00), control be5z-2c19-h ($568.44) and labor ($1800) plus tax. 

 

This is a huge bill.  I bought the car used in 2012 with 40K miles and have had no major issues other than the air conditioner which was fixed under an extended warranty I purchased.  I like the car and its paid for.  Wasn't really looking to purchase a new car at this point.  As a trade in, the car is worth $5,500  $6,000 so I am leery about paying so much to fix.  Also, not sure how long the hybrid battery will last (warrant says 8yrs or 100K which I am past on both).  Anybody have a similar issue with  brake issue and the repairs the dealer is recommending?  Does the repair price seem  reasonable?  Any feedback is appreciated.

[murphy]

8 years or 100,000 miles was the warranty.  The hybrid battery is supposed to last for the life of the car.

 

I find it strange that two weeks after they replaced the brake fluid the brakes don't work.

 

The brake booster is electric since it has to work when the engine isn't running and vacuum isn't available.

 

The first thing they should have done, IMHO, is purge the brake lines to guarantee there is no air in them.

 

I had a 2010 Fusion Hybrid, bought new in April 2009, and did not have any problem with the brakes.  I traded it in on a 2013 Fusion Energi in April 2013 so it never had high mileage while I owned it.

 

 

[Waldo]

Could be when they flushed the fluid, they just didn't bleed the system out properly (requires hooking up the computer and cycling the ABS system).  But it could also be that the reason your fluid was low in the first place was because there's a leak somewhere.   It is highly unlikely though that all three of those major components would fail at the same time.  Seems like they are just guessing and want to throw the book at it.  For that high a repair bill, it certainly wouldn't hurt to get a second opinion, or at least try a proper bleed again first.  

Edited August 10, 2021 by Waldo

[CAI]

15 hours ago, murphy said:

8 years or 100,000 miles was the warranty.  The hybrid battery is supposed to last for the life of the car.

 

I find it strange that two weeks after they replaced the brake fluid the brakes don't work.

 

The brake booster is electric since it has to work when the engine isn't running and vacuum isn't available.

 

The first thing they should have done, IMHO, is purge the brake lines to guarantee there is no air in them.

 

I had a 2010 Fusion Hybrid, bought new in April 2009, and did not have any problem with the brakes.  I traded it in on a 2013 Fusion Energi in April 2013 so it never had high mileage while I owned it.

 

 

 

15 hours ago, murphy said:

8 years or 100,000 miles was the warranty.  The hybrid battery is supposed to last for the life of the car.

 

I find it strange that two weeks after they replaced the brake fluid the brakes don't work.

 

The brake booster is electric since it has to work when the engine isn't running and vacuum isn't available.

 

The first thing they should have done, IMHO, is purge the brake lines to guarantee there is no air in them.

 

I had a 2010 Fusion Hybrid, bought new in April 2009, and did not have any problem with the brakes.  I traded it in on a 2013 Fusion Energi in April 2013 so it never had high mileage while I owned it.

 

 

Thanks Murphy for the feedback.  I will ask if they tried purging the brake lines.

[CAI]

14 hours ago, Waldo said:

Could be when they flushed the fluid, they just didn't bleed the system out properly (requires hooking up the computer and cycling the ABS system).  But it could also be that the reason your fluid was low in the first place was because there's a leak somewhere.   It is highly unlikely though that all three of those major components would fail at the same time.  Seems like they are just guessing and want to throw the book at it.  For that high a repair bill, it certainly wouldn't hurt to get a second opinion, or at least try a proper bleed again first.  

Thanks Waldo.  Good insight on "all three major components failing at the same time". I will question that and also ask about if bleeding the system was done correctly as you described.  If that doesn't pan out, would you get a second opinion from another Ford dealer or look for an independent mechanic?

[Mark J]

I have two 2010 Fusion's, gas V6 SEL and Hybrid. There is a current recall for the gas SEL concerning the HCU.  Recall number 19S54 HCU valve concern(17X29). Has to due with a chemical reaction between DOT3 brake fluid and the zinc plating inside the unit, possibly gelling up internal parts causing them to stick open, resulting in longer brake pedal travel increasing required distance to stop. Does not result in loss of braking function. The dealer will test the unit for correct operation and replace if needed. If good, system flushed and DOT4 fluid will be put in.  My appt is next week.  This recall has been around for a quite a while. Parts availability holding it up apparently. Not sure if Hybrid uses same part numbers for the abs hydraulic control system.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Edited August 13, 2021 by Mark J

[Mark J]

Forgot to mention, this recall has been around for a quite a while. Parts availability holding it up apparently.