2020 Ford Fusion

I am reporting a life-threatening incident involving my 2020 Ford Fusion PHEV. On December 5, 2025, while my wife was driving on a public street, the vehicle suffered a sudden, complete engine failure followed by smoke and fire originating from the high-voltage battery pack in the trunk. There were no prior warning signs or dashboard alerts before the incident. This vehicle was sold via IAAI auction in September 2023 without disclosing the active, critical safety recall (NHTSA 23V440 / Ford 23S33) issued in June 2023. This non-disclosure placed my family in extreme danger. When the fire started, my wife was in a state of panic. I arrived at the scene before emergency services. Being a technician, I performed a high-risk manual extraction of the burning battery pack to prevent the entire vehicle and the surrounding residential area from a potential explosion. I risked electrocution and toxic chemical exposure to save lives. The damaged battery pack is currently preserved and available for professional inspection upon request. As a result of the fire and exposure to extinguisher chemicals, I suffered respiratory distress and asthma-like symptoms for several days. I have contacted Ford Motor Company through official channels and documented all interactions. Ford representatives stated that they 'only assist customers in the United States' and local representatives in [XXX] have officially refused to provide the remedy, stating they are not authorized or equipped for this specific recall. I am now left with a charred, unusable vehicle. I demand a full investigation into the failure of the recall remedy process and manufacturer liability for these life-threatening damages. ( Form fields about my location are place holders. Contact me in [XXX] (Country) at [XXX] / [XXX] ]. I hope you do don't ignore our lives due to geography. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

"The incident occurred immediately after shifting the vehicle into reverse and starting to move. The engine suddenly shut down with a 'System Performance' alert, and cooling fans engaged at maximum speed. Moments later, a thermal runaway event began in the high-voltage Li-ion battery pack, leading to a catastrophic fire. This is directly related to Recall 23V440 / 23S33 (BECM failure). The fire was extinguished by the local fire department in Telavi, Georgia (Country)."

In early October 2025, the vehicle was taken to an independent dealership service department for a routine oil change. Several weeks later, the vehicle appeared to be leaking fluid and began experiencing loud knocking/clacking noises, significant vibration, and drivability concerns, especially during acceleration. On October 10, 2025, while parked at a family member’s residence, the vehicle would not start. Due to safety concerns, the servicing dealership arranged for the vehicle to be towed for inspection. Technicians found a split transmission hose causing transmission fluid loss, which was repaired; however, the abnormal noises, vibration, and drivability issues persisted. Further inspection identified loud popping/clacking noises from the bell housing area. The technician physically inspected the flex plate and documented that the flex plate was cracked. The dealership advised that a cracked flex plate can worsen, cause severe vibration, damage related components, and lead to drivability issues or potential loss of propulsion. Because of the nature of the failure and symptoms, the vehicle was removed from regular use due to safety concerns. The vehicle was later taken to a manufacturer-authorized Ford dealership, which confirmed flex plate failure but stated the vehicle did not qualify for a customer satisfaction program due to engine variant. A goodwill/financial assistance request was submitted and denied. Technician diagnostic documentation from the manufacturer-authorized dealership was requested but not provided prior to filing this complaint. No crash or injury occurred; however, the failure created a risk of sudden inability to propel the vehicle while driving, including at highway speeds. The vehicle remains unrepaired and parked due to cost and safety concerns.

My Ford started making a loud noise whenever the accelerator wasn't being pressed, after taking it to the mechanic, he said it is the cracked flex plate. After some light research, it was aparent that this is an issue that Ford's cars have, and ford has tried to make it better by offering free fixes. I contacted the local ford dealer and since the car has 90,000 miles, it would have been covered. However, since it doesn't have a clean title, I was declined this service free of charge. I don't agree with this decision since I've been driving this car for over a year since it was purchased off IAA auction, and this issue was made clear only yesterday, but this issue is prevalent in cars like mine.The damage to my car specifically was to the back, and only affected the rear bumper and trunk. Therefore I don't think it is fair that I was declined the serve even though Ford has made it clear it is there manufacturing mistake and they are willing to fix it, just not with cars with my type of title. I was hoping to send in this incident so that this issue becomes a national recall, and more people can get their cars rightfully fixed and aware of this serious issue that can make the car completely unusable before it gets too late. I wasn't aware this was a common issue when purchasing this car, so a recall would protect more people since it will become mandatory information for owners to be aware of this issue. Thank you!

My 2020 Ford Fusion has experienced three separate flexplate failures, as well as transmission issues following the most recent repair. Failure #1: Occurred before I owned the vehicle (confirmed later in the vehicle’s history). The flexplate was replaced by a prior owner in 2022. Failure #2: [8/2023] – While I owned the vehicle, a loud rattling noise came from the engine area. My vehicle was towed to Foothill Ford, where it was purchased, and they replaced the flexplate. No power loss occurred. Failure #3: [5/2025] – The same rattling sound returned. I drove it to Green Ford, who confirmed the flexplate needed to be replaced, and they replaced it. No power loss occurred, but the noise was severe. After the third flexplate replacement, the transmission began slipping during acceleration. This issue did not exist before the repair, and Green Ford had told me the transmission was fine before they replaced the flexplate. Safety concern: Repeated flexplate failures and subsequent transmission slipping could cause loss of propulsion or difficulty maintaining speed if the problem occurs at highway speeds or in heavy traffic, creating a potential crash risk. I did lose power on the highway, but was able to pull safely off the shoulder and called a tow truck.