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Ford Fusion Energi PHEV Recalled Over Increased Fire Risk From Damaged Control Module

Ford Fusion Energi 7 photos
Photo: Ford / edited
Ford Fusion EnergiFord Fusion EnergiFord Fusion EnergiFord Fusion EnergiFord Fusion EnergiFord Fusion Energi
Revealed with much pomp in 2012 at the North American International Auto Show in Detroit, the Fusion Energi plug-in hybrid was discontinued in 2020 together with its lesser siblings. The Ford Motor Company canned pretty much every car in the North American lineup due to rising demand for crossovers and trucks, leaving the 'Stang to soldier on alone.
Ford's latest recall concerns a handful of Energi vehicles manufactured for the 2019 and 2020 model years at the Hermosillo Stamping and Assembly Plant in Mexico. Build dates range from December 6, 2017 through July 27, 2020.

What is the problem with the 14,452 sedans produced in said timeframe? As it happens, the battery energy control module may be damaged by current interrupt device activation. CID activation results in excess voltage and current flow through the BECM, which leads to a loss of motive power or a fire in the BECM's area. Ford has yet to determine the root cause for the current interrupt device activation in the battery cells.

The Trend and Early Warning Support team within FoMoCo informed the safety boffins about this matter in July 2022, with the TEWS reporting five allegations of fire in the cargo area of the Fusion Energy. Said incidents occurred between March 2022 and May 2022 while the plug-in hybrid sedans were in service for a replacement battery energy control module.

The vehicles in question were there for diagnostic trouble codes and other problems, including a no-start condition, loss of motive power, and check engine light. Two additional fires occurred between May 2023 and June 2023, bringing the grand total to seven. Worse still, Ford is aware of 270 warranty claims alleging a loss of motive power due to this issue.

Thankfully, no accidents or injuries have been reported thus far. Ford's temporary fix for this condition is… wait for it… some advice. More specifically, owners are urged to refrain from charging their plug-in hybrid sedans. A lower charge level in the high-voltage battery reduces the risk of localized fire and loss of motive power. Owners will be informed about the definitive remedy once the root cause is determined.

Dealers have already been informed of this problem, whereas known owners of the 2019 and 2020 Ford Fusion Energi will be notified no later than July 28. In the meantime, running the vehicle identification number on the National Highway Traffic Safety Administration's online portal is the easiest way to determine whether your Fusion Energi is recalled or not.

As a brief refresher, the Mondeo is a goner from the European lineup as well. The Fusion's cousin was produced in Spain at the Valencia Body & Assembly Plant. Changan Ford continues to make a sleek-looking Mondeo in China for a few markets, including the Middle East, where the mid-size sedan is called Taurus. The fifth-gen Mondeo, however, isn't meant for the Old Continent or the United States of America.
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 Download: Ford Fusion Energi PHEV recall (PDF)

About the author: Mircea Panait
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After a 1:43 scale model of a Ferrari 250 GTO sparked Mircea's interest for cars when he was a kid, an early internship at Top Gear sealed his career path. He's most interested in muscle cars and American trucks, but he takes a passing interest in quirky kei cars as well.
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