Transmission leak, electrical failures at 15K

[txags99]

Purchased a 2014 Fusion Titanium Hybrid last summer. Has been babied and garage kept and now at 15,000 miles. Was pleased with the car at first even though it has never averaged more than 38.5 mpg. Things have gone from bad to worse and I'm now seeking advice on what to do next? Here's the short version:

 

On its first (early) oil change, a Ford dealer tech made a small hole in the oil filter causing a slow leak and it took about a month before I noticed oil on the garage floor due to the aerodynamic cover under the engine. Luckily, I noticed it at all and put a new filter on myself and topped the oil level (1.5 quarts low). While underneath the car I found transmission fluid leaking from the transmission housing and pointed it out to (a different) dealer at the next oil change. The cover and the undercarriage of our "new" car is still soaked with oil despite my attempts to clean it up.

 

A few weeks ago I dropped the car off so the transmission could be re-sealed. Also asked for repair of what sounds to be like a bad half shaft or bearing popping on the driver's side at low speeds, of course dealer could not duplicate. Dealer turned the car quickly and all seemed fine with the transmission nonetheless.

 

Last Wednesday, I was on the way to the store at 9:30 PM, the car made a "pop" noise from the left side under the hood and immediately lost power. The "stop safely now" and triangle illuminated on the ip and the car stalled and would not re-start. I called roadside assistance and they picked the car up on a flatbed.

 

The dealer called Thursday and stated that the car had blown a 125 amp fuse and they were looking for the root cause. Dealer called Friday and reported that they had ordered over $6,000 worth of electrical components, including the A/C compressor. Said they think the A/C compressor shorted out and took several other components with it as well. Isn't the purpose of a fuse to protect electrical components?

 

I asked if the car would ever be the same and how long the repairs might take because I am paying for a rental every day it is in the shop. The service writer was personable, but could not really give me an answer and said he'd call when more information becomes available.

 

Has anyone else's car ever blown the 125 amp fuse? Is this car doomed? Can it be fixed or should I seek help from Ford or legal aid? What has happened to quality at Ford? My 2013 f-150 Lariat 4X4 has been pretty bad with numerous warranty visits, including leaks, but it never died on the road and left me stranded.

 

This Fusion Hybrid appears to be a lemon and I'm not comfortable with my wife driving it if we ever get it back from the dealer. Really disappointed because I have owned several good Ford trucks and have recommended many Ford products to friends and neighbors.

 

Anyone been in this situation? Advice?

Edited March 30, 2015 by txags99

[md13ffhguy]

Sorry for your misfortune. I don't know about the problems you're having, but #1, I would insist that Ford cover the rental, and #2, they should replace the oil-soaked aerodynamic cover. Hopefully, your service technicians can figure out the rest for you.

[lolder]

I don't understand why an AC compressor would blow a fuse that disabled the car. The car's under warranty so they have to fix it.

[txags99]

I am also having trouble understanding why $6,000 worth of electrical parts would fail simultaneously. What on earth could cause something like this to happen? I also wonder if a ground or harness was improperly connected when they took the transmission out of the car to fix the leak a couple of weeks ago?

[Easy Rider]

Advice?

First, if you are still within your "bumper to bumper" warranty period, you should NOT be paying for a rental car.

Ford should be supplying you a "loaner".

 

Second, I think I'd be nervous too if I was in your situation.

I'm sure the car CAN be fixed to a "like new" condition but whether or not it WILL be might be in question.

 

I suggest that you contact the "warranty help" people at Ford; number listed in your warranty book AND that you start looking into the "lemon laws" in your state.

Once in a great while, just mentioning the lemon law will trigger an offer for a trade.

[Easy Rider]

I am also having trouble understanding why $6,000 worth of electrical parts would fail simultaneously.

It doesn't happen simultaneously; it happens sequentially, a cascade effect.

[FordService]

Purchased a 2014 Fusion Titanium Hybrid last summer. Has been babied and garage kept and now at 15,000 miles. Was pleased with the car at first even though it has never averaged more than 38.5 mpg. Things have gone from bad to worse and I'm now seeking advice on what to do next? Here's the short version:

 

On its first (early) oil change, a Ford dealer tech made a small hole in the oil filter causing a slow leak and it took about a month before I noticed oil on the garage floor due to the aerodynamic cover under the engine. Luckily, I noticed it at all and put a new filter on myself and topped the oil level (1.5 quarts low). While underneath the car I found transmission fluid leaking from the transmission housing and pointed it out to (a different) dealer at the next oil change. The cover and the undercarriage of our "new" car is still soaked with oil despite my attempts to clean it up.

 

A few weeks ago I dropped the car off so the transmission could be re-sealed. Also asked for repair of what sounds to be like a bad half shaft or bearing popping on the driver's side at low speeds, of course dealer could not duplicate. Dealer turned the car quickly and all seemed fine with the transmission nonetheless.

 

Last Wednesday, I was on the way to the store at 9:30 PM, the car made a "pop" noise from the left side under the hood and immediately lost power. The "stop safely now" and triangle illuminated on the ip and the car stalled and would not re-start. I called roadside assistance and they picked the car up on a flatbed.

 

The dealer called Thursday and stated that the car had blown a 125 amp fuse and they were looking for the root cause. Dealer called Friday and reported that they had ordered over $6,000 worth of electrical components, including the A/C compressor. Said they think the A/C compressor shorted out and took several other components with it as well. Isn't the purpose of a fuse to protect electrical components?

 

I asked if the car would ever be the same and how long the repairs might take because I am paying for a rental every day it is in the shop. The service writer was personable, but could not really give me an answer and said he'd call when more information becomes available.

 

Has anyone else's car ever blown the 125 amp fuse? Is this car doomed? Can it be fixed or should I seek help from Ford or legal aid? What has happened to quality at Ford? My 2013 f-150 Lariat 4X4 has been pretty bad with numerous warranty visits, including leaks, but it never died on the road and left me stranded.

 

This Fusion Hybrid appears to be a lemon and I'm not comfortable with my wife driving it if we ever get it back from the dealer. Really disappointed because I have owned several good Ford trucks and have recommended many Ford products to friends and neighbors.

 

Anyone been in this situation? Advice?

Welcome to the forum, txags99.

 

I want to take a peak under the hood, so to speak, and send this along to your customer service manager. Please send me a private message with your VIN, mileage, best daytime phone number, full name, and dealer name/location.

 

Meagan

[hybridbear]

Also, get our Ford Service rep involved. Search for username FordService and send her a PM.

 

Edit: I see Meagan beat me to it. :)

Edited March 30, 2015 by hybridbear

[acdii]

Short answer to can one device cause this much damage. YES.

 

The fuel pump in a 1992 Crown Vic I had, shorted out one day and took out all the wiring in the trunk.

 

Since the AC compressor is DC right from the HVB, it draws a lot of amps, so if it does go south, it can cause a lot of damage if the fuse doesn't blow in time, which is what happened with the Vic, It drew too much current, but not enough to blow the fuse, then eventually so much current was flowing that the wires melted then caused a direct short that immediately fried all the wiring involved before the fuse popped.

 

As for your car, other than the oil leak caused by the other dealer, who I would have harrassed to no end until the car was spotless again, and the trans fluid leak they missed, did everything else work? Ignore the MPG for now as that could be just about anything, and you are getting between 38 and 43 which is what these cars should get on average.

[lolder]

The AC compressor can probably draw a few thousand watts, lets say three. I'm not sure what voltage is delivered , maybe 300 so that would only be 10 amps. 100+ amp fuses would be for the motor control electronics IGBTs. That would disable the car. There are two IGBTs, one for each M/G. There may be one built into the AC compressor also.

[FordService]

Also, get our Ford Service rep involved. Search for username FordService and send her a PM.

 

Edit: I see Meagan beat me to it. :)

:victory: Thanks for the shout-out, anyway!

 

Meagan

[txags99]

The air conditioner compressor, a wiring harness, and some other electrical components were ultimately replaced on that visit. Since then, the A/C compressor has gotten louder and started making a "knocking" noise especially after start up on a hot day. The wheel well liner on the right front also fell down on the tire burned holes into the plastic and I had to tie it up with zip ties so the car could be driven. The oil-soaked cover under the car is also sagging and torrn from where the tow truck driver incorrectly hooked the underside or the car, tore it and I'm sure the oil saturation isn't helping matters either.. Several of the plastic clips holding these covers or liners on under the car are now missing as well like they have just fallen out.

 

I dropped the car off at the local dealer that did the previous work almost two weeks ago and today they told me that the a/c compressor is "normal" and that I would have to foot the bill to replace the wheel well liner even though they couldn't tell me why it dislocated itself and the plastic clips keep falling out. In the meantime we've had to rent another car while the FFH sits in the shop AGAIN with 25k miles on the odometer. It's not the cost that is the issue, it's the question of why is this car having so many problems and why should I have to be inconvenienced and stuck with paying for something this poorly built?

 

Is anyone else having similar experiences with the a/c compressors causing electrical problems and being so loud that people stare at your car in parking lots? What about clips and covers sagging and falling off under the car. Do these cars ever get fixed and operate dependably in the long run? Very concerned about owning this one outside of warranty at this point!

[GrySql]

txags99,

Sounds like you need the help of our Forums Ford Customer Service Rep.

Send Meagan a Private Message here: http://fordfusionhybridforum.com/user/12405-fordservice/

[DeeCee]

No such problems on my 2013 Job 1 FFH with about 48K miles now.

[GrySql]

No such problems on my 2013 Job 1 FFH with about 48K miles now.

You got a real good one. Have you had all the Recalls done?

[txags99]

This is what the covers under the car look like after it's leaked transmission fluid and oil all over the place. Between the fluids, numerous removals and installations for repairs, and the tow truck driver that apparently did not know how to properly pick the car up, they are sagging and apparently having trouble staying in place. Pretty ridiculous that Ford won't step up and fix this stuff. It also stinks when the car gets hot and will likely kill resale value when I try to trade it. Glad you haven't had any trouble DeeCee,, we initially liked ours otherwise.

[GrySql]

This is what the covers under the car look like after it's leaked transmission fluid and oil all over the place. Between the fluids, numerous removals and installations for repairs, and the tow truck driver that apparently did not know how to properly pick the car up, they are sagging and apparently having trouble staying in place. Pretty ridiculous that Ford won't step up and fix this stuff. It also stinks when the car gets hot and will likely kill resale value when I try to trade it. Glad you haven't had any trouble DeeCee,, we initially liked ours otherwise.

Did you send a message to our Ford Rep, your situation needs arbitration, don't wait.

[DeeCee]

You got a real good one. Have you had all the Recalls done?

No. The following are outstanding:

Recall 15S14, steering motor bolts - N/A as Arkansas is not considered to be a "corrosion state".

Recall 14S21, airbag restraint control module - waiting for notification parts are available. Not a big concern as long as the airbag warning light does not illuminate.

Recall 15S16, door latch replacement - waiting on notification that parts are available.

Recall 14E02, PCM reprogram for emission glitch- Just have not been in for service in a while. Will probably get done at next visit.

[mnb76]

I also had transmission leak in my 2014 SE after only 42900 miles and they eventually replaced the transmission.

That was March 2018. Now in Sept 2018 I experienced the dreaded "Stop Safely Now"

 

I was backing out of a parking space and the car just shutdown with a shudder and I saw the red triangle and "Stop Safely Now" on the dash.

I cycled power and tried to drive again and it did it again after 20 feet of driving. Now I was sticking out in a lane in the parking lot so I tried one more time to move the car. Again, the SSN message came up but I kept driving on electric only (at about 2 miles/hr) until I could get to another safe parking lot and out of the way.

 

I had the car moved via flatbed to the Ford dealer and for the last few days they have been trying to fix it. At first they couldn't duplicate but once they did, the "fix" was to reflash the PCM. They kept the car another day to test it and then it failed five times in a row.

One more day at the dealer and now they tell me they have ordered new high voltage cables that run between the PCM and the transmission.

These will be replaced once they come in and I hope that fixes it.

 

I wonder if the repair in March 2018 to replace the transmission somehow caused this problem to eventually appear?

 

In any case, I'm not feeling too comfortable with this car anymore.

[mnb76]

Well they tried replacing the hi voltage cables but that didn't fix it. They had a valet/porter test-drive the car after the cable replacement and it died on him the same way it did to me. Stop Safely Now appeared on the dash. He tried multiple times to get it going but could not. They had to tow it back to the dealership. (My car is spending a lot of time getting rides on flatbed trucks.)

 

They think there is a problem in the transmission so they are going to look at it again.

 

This is ridiculous.

 

Also I find it hard to believe that when the car decides to stop with the SSN message that the software doesn'tstore a set of codes in memory that can be used to diagnosis the issue. The software is telling the car to shutdown so it should store the reason in flash so that someone can figure it out later.

 

I've now been without my car for nine days.