Diagsheet

2016 Ford Fusion · symptom sheet

Brakes grind, pulse or wear early

  • 133owner reports
  • 80,000median miles
  • $585median quote
  • 14involved a crash

Newest report Aug 14, 2026 · checked Sep 9, 2026

133 of the 1,614 complaints on this car describe brake wear.

Tick what matches of 133 reports

6
6
34
9
66
10

What got replaced

Owners who name the part that was replaced mention the ABS module (13 reports), the pads and rotors (9 reports), the booster (7 reports) and the caliper (3 reports).

Recalls and investigations

One recall on the brakes covers the 2016 model year. A recall on the same system isn't always the same failure, so read the defect text.

23V-162Mar 10, 2023
Service Brakes, Hydraulic:Foundation Components:Hoses, Lines/Piping, And Fittings

Ford Motor Company (Ford) is recalling certain 2013-2018 Fusion and Lincoln MKZ vehicles. The front brake hoses may rupture and leak brake fluid.

Risk and remedy
Risk: A brake fluid leak will increase brake pedal travel and extend the distance needed to stop the vehicle, increasing the risk of a crash.
Remedy: Dealers will replace the front brake hoses, free of charge. Owner notification letters were mailed June 27, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S12.

NHTSA investigations into the brakes on the Fusion

RQ22-004opened Aug 8, 2022
Service Brakes, Hydraulic · model years 2013 to 2018

Front brake jounce hose failures. Closed mar 24, 2023, led to recall 23V-162.

NHTSA summary
On August 8, 2022, the Office of Defects Investigation (ODI) opened this investigation based on 50 Vehicle Owner Questionnaires (VOQs) alleging front brake jounce hose ruptures on model year (MY) 2013-2018 Ford Fusion and Lincoln MKZ vehicles. A ruptured front brake hose results in a brake fluid leak. As a result, the driver may experience an increase in pedal travel and a reduction in the rate of deceleration, increasing the risk of a crash. It should be noted that the subject vehicles identified fell outside the scope of NHTSA Safety Recall 20V-469, which addressed front brake hoses rupturing on certain MY 2015-2018 Ford Edge and 2016-2018 Lincoln MKX vehicles. The result causes a brake fluid leak, lengthening the distance needing to stop the vehicle, increasing the risk of a crash.On March 10, 2023, Ford Motor Company (Ford) submitted to NHTSA Safety Recall 23V-162 (Ford Recall 23S12) to address front brake jounce hoses that may rupture. Ford found the rupture occurs from a localized failure of the internal reinforcement braid due to cyclic fatigue through tensile/bending and torsional inputs during suspension and steering articulations. The supplier for the front brake jounce hoses is Hitachi. This recall affects the subject vehicles equipped with non-hybrid engines and the suspect front brake jounce hoses (a total of 1,280,726 vehicles). The recall covers subject vehicles built from February 3, 2012 to July 19, 2017 when the suspect hoses were used in vehicle production.
EA18-002opened Apr 18, 2018
Service Brakes, Air · model years 2007 to 2009

Extended braking distance. Closed jan 15, 2021, led to recall 19V-904.

NHTSA summary
On April 18, 2018, the Office of Defects Investigation (ODI) opened Engineering Analysis (EA) 18-002 to investigate reports of braking concerns in model year (MY) 2006-12 Ford Fusion and Lincoln MKZ, and MY 2006-11 Mercury Milan vehicles manufactured with Continental Automotive System?s ABS hydraulic control units (HCUs). Complainants report that after an ABS braking event (initiated by slippery or uneven surfaces) the brake pedal moved towards the floor and the vehicle stopping distance increased beyond driver expectations.Inside the HCU are four hydraulic normally closed (NC) valves with zinc-coated moving armatures that control the flow of brake fluid. Unstable brake fluid can degrade over time, allow the brake fluid to gel, and corrosion to form on the armatures. The high-viscosity gelation and corrosion can cause the armatures to become stuck (open). In some cases, braking returns to normal when the armature(s) subsequently become unstuck. The intermittent condition proves difficult to diagnose with complainants reporting having (non-HCU) repairs conducted only to have the condition return.During the investigation, 14 HCUs from complaint vehicles were recovered, including seven from reported crashes. NHTSA?s Vehicle Research and Test Center (VRTC) disassembled the HCUs, removed the four NC valves in each, and confirmed 22 of the 56 NC valves contained stuck armatures. On seven of the 14 HCUs, both front wheel armatures were stuck, on nine of the 14 HCUs two or three arma
PE16-017opened Dec 20, 2016
Brakes · model years 2007 to 2009

Extended braking distance. Closed may 4, 2018.

NHTSA summary
On December 20, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation (PE) 16-017 to investigate reports of braking concerns in model year 2007 through 2009 Ford Fusion and Mercury Milan vehicles.Complainants report that after an ABS braking event (caused by braking on a slippery or uneven surface) the brake pedal moved towards the floor and the distance in which the vehicle stopped increased beyond what was expected by the driver.The cause of the problem appears to be the Antilock Braking System (ABS) Hydraulic Control Unit (HCU), a component manufactured for Ford by Continental Automotive Systems.Hydraulic control valves within the HCU can experience corrosion and become stuck.In some cases, braking returns to normal when the valve(s) subsequently become unstuck.The intermittent condition proves difficult to diagnose and complainants report having several brake system components replaced only to have the condition return.ODI has identified 544 reports submitted to the agency that relate to this issue in model year 2006-2012 Ford Fusion/MKZ and MY 2006-2011 Mercury Milan, the subject vehicles.Complainants report an increase in pedal travel which in some cases resulted in going past expected stopping points or having to steer to avoid contacting another vehicle; twenty six report a crash with 3 injuries alleged.The Ford reports shown above, which are from PE16-017 and involved the scope discussed above, were similar in content and identified 7 crashes

What owners paid

9 of the 133 reports quote a price. Each dot is one quote. The middle half runs $191 to $600.

$191$585$600
$0k$2k$4k$6k$8k

When it happens

The middle half of failures fell between 50,000 and 110,000 miles, from the 61 reports that gave a mileage.

316
417
718
519
520
321
1322
6423
1024
1125
826

What owners wrote

“I take it to mechanic they say my car have transmission problems is making lot noise and stop and go really crazy. The dealer say there is nothing wrong with car. The. Brakes sometimes get me scared when I drive I feel we r not safe. No and they can’t fix it because they don’t have the part for the brakes. The msg was check owner manual something like that which can mean lots different problems in ur vehicle.”

Filed Jun 2, 2023

“I began receiving a brake line warning that my system was leaking, and needed to be filled. I replaced the brake fluid in my vehicle, and less than two hours later the car said the same warning. I couldn’t brake without pushing the brake all the way too the floor”

Filed Apr 17, 2023

“I was driving and when I proceeded to brake I felt something pop and my brake peddle went all the way down I could feel like air”

Filed Apr 5, 2023

“Brake line hose burst causing the brakes to fail while driving . I was not able to stop the car had to pull the emergency brake.This is the third time in two years.”

Filed Mar 8, 2023

Should you keep driving it?

This page can't tell you that. 14 of 133 reports involved a crash and 6 people were hurt. Owners who file are the ones who had a bad experience, and nobody checks their reports. If the problem affects steering, braking, power or a fire risk, treat it as a safety fault and have it inspected before a long or high-speed drive.

File your own report with NHTSA. Complaint counts are how a problem gets an investigation.

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