2012 Ford Fusion: what breaks, and at what mileage

What breaks on the 2012 Ford Fusion

Owners have reported 80 named failure modes on the 2012 Ford Fusion, and the three most-reported carry 47% of everything filed.

Other steering problem leads with 896 reports, about 14 per 1,000 vehicles and with the middle half of reports between 50k to 126,000 miles.

Airbag inflator rupture follows with 277 reports, usually reported between 50k to 110,000 miles.

Loss of power steering follows with 275 reports, usually reported between 41k to 115,000 miles.

By system, the reports fall mostly into steering (1,405), airbag (322) and electrical (201).

Severity, and what it costs

Across the named modes, 142 mention a crash, 11 a fire, 54 an injury and 7 a fatality. Those are the words owners used in their own complaints, and NHTSA does not verify them, but they are the closest thing in this data to a measure of what a failure actually did.

The average severity weight across every report on this year is 4.80, where a stalled engine or a failed airbag weighs many times more than a rattling trim panel, and a figure this high means the reports are dominated by failures with safety consequences rather than annoyances. The weighting is set out in full on the methodology page.

What the top failures cost to put right, as editorial estimates for an independent US shop rather than figures from NHTSA: other steering problem at $350–$2,400, airbag inflator rupture at $0–$0, loss of power steering at $600–$2,800 and steering rack, gear or tie rod failure at $700–$2,600. Dealer labour, a seized bolt or a part that is no longer made can push any of these past the top of its range.

10% of the reports on this year sit in the engine, transmission, drivetrain or cooling systems — the four where a repair bill is usually four figures.

How often, against how many were built

Scaled by an estimate of how many of these cars exist, the 2012 Ford Fusion draws about 47 per 1,000 vehicles, which puts it in the 97th percentile of complaint rates among 2012 vehicles we can rate.

That denominator is the weakest number on the page and it is fair to say so plainly. Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound.

The working figure is 65,066 vehicles. If the true number is twice that, every rate on this page is half what it says; the ranking against other 2012 vehicles, which is what the risk score uses, is far more robust than the rate itself.

Recalls on the 2012 model year

NHTSA has issued 6 recall campaigns covering the 2012 Ford Fusion, affecting an estimated 145,561 vehicles. A recall is a different kind of evidence from a complaint: it is the regulator and the manufacturer agreeing that something has to be fixed, and the fix is free for as long as the car exists.

The campaigns cover air bags:frontal:driver side:inflator module, air bags:frontal and air bags:frontal:passenger side:inflator module. Whether the work was actually done on the car in front of you is a question only the VIN can answer, and the manufacturer or NHTSA will answer it free.

Recalls also distort complaint counts. Publicity about a campaign reminds owners that complaining is possible, so reports for a recalled component often spike after the recall rather than before it.

Where 2012 sits in the model line

High risk for a 2012 — 81st riskiest of the 271 2012 vehicles we can rate. Because the ranking is against the same model year only, age cancels out of it.

Across the 15 model years of this car that carry enough reports to score, 2018 comes out best at 68 and 2010 worst at 76, with 2012 itself at 74.

If the model year is negotiable, 2018, 2007, 2008 and 2006 score lower than 2012 by a margin worth acting on. Same body, same engines, different luck — usually a supplier change or a mid-cycle fix, which the complaint data can show but never explain.

Within the 2010–2012 generation specifically, 2012 is the strongest year at 74 and 2010 the weakest at 76.

Where to spend the inspection money

The mileages below are where the first quarter of reports for each mode had already been filed, which makes them the point at which a fault is worth looking for rather than the point at which it happens: other powertrain problem from about 17k, no-start or intermittent start failure from about 19k, other engine problem from about 21k and other fuel system problem from about 25k.

On a 2012 Ford Fusion with more miles than that on it, the useful question to put to a seller or a mechanic is whether other powertrain problem has been dealt with, and if so with what parts and at whose expense. A car that has already had the repair is in a different position from one that has not.

None of this is a diagnosis. It is a list of what other owners of the same model year reported, ordered by when they reported it, which is a good place to point an inspection and a poor place to stop.

Where these figures stop being useful

3,059 owner reports; fleet size estimated from this year's own recall paperwork. Every count on this page is therefore a floor: it is the number of owners who went to the trouble of filing with a federal agency, which is a small and self-selected fraction of the owners who had the fault.

Of those 3,059 reports, 2,126 carried an odometer reading, so the mileages here describe 69% of the sample rather than all of it. Owners also round: readings pile up on multiples of ten thousand, which is why this site publishes "about 90,000 miles" and not "91,438".

Named failure modes come from matching phrases in the complaint text, so a badly worded complaint can land in the wrong bucket. The effect washes out across hundreds of reports and does not wash out across five.

And nothing here predicts what one car will do. These are other people's complaints, filed years apart, on cars maintained by strangers. Read the page as a map of where this model year has previously gone wrong, then have the specific car in front of you inspected.