The 2020 Ford Fusion is associated with 229 official NHTSA owner defect complaints and 3 safety recall campaigns in the federal safety database. The most frequently reported component area is Electrical System, accounting for 51 reports (22% of total complaints). EPA testing covers 8 certified vehicle configurations spanning 1.5l 4-cyl, 2l 4-cyl, 2.5l 4-cyl, 2L 4-Cyl hybrid, and 2L 4-Cyl plug-in hybrid configurations. Gasoline and hybrid variants deliver 23 to 42 MPG combined. Plug-in hybrid variants are rated up to 103 MPGe (42 MPG on gasoline) with up to 26 miles of electric driving range.
Key Data Findings
- • NHTSA Owner Complaints: 229 reports
- • Safety Recall Campaigns: 3 campaigns
- • Top Reported Defect Area: Electrical System (51 / 22%)
- • Safety Incident Signals: 11 crash / 4 fire / 6 injury reports
- • NHTSA Overall Safety Rating: 5 / 5 Stars
- • EPA Efficiency: 23–42 MPG (8 variants • PHEV up to 103 MPGe)
Data Note: Compiled directly from official NHTSA Office of Defects Investigation (ODI), NHTSA 5-Star Safety Ratings, and EPA FuelEconomy.gov databases.
| Variant | Engine | Drivetrain | Transmission | City | Highway | Combined | EV Range | Est. Annual Fuel Cost |
| Fusion FWD | 1.5L 4-Cyl | Front-Wheel Drive | Automatic (S6) | 23 MPG | 34 MPG | 27 MPG | — | $2,300 / yr |
| Fusion FWD | 2L 4-Cyl | Front-Wheel Drive | Automatic (S6) | 21 MPG | 31 MPG | 25 MPG | — | $2,450 / yr |
| Fusion FWD | 2.5L 4-Cyl | Front-Wheel Drive | Automatic 6-spd | 21 MPG | 31 MPG | 24 MPG | — | $2,550 / yr |
| Fusion AWD | 2L 4-Cyl | All-Wheel Drive | Automatic (S6) | 20 MPG | 29 MPG | 23 MPG | — | $2,650 / yr |
| Fusion Hybrid FWD Hybrid | 2L 4-Cyl | Front-Wheel Drive | Automatic (variable gear ratios) | 43 MPG | 41 MPG | 42 MPG | — | $1,450 / yr |
| Fusion Hybrid Taxi Hybrid | 2L 4-Cyl | Front-Wheel Drive | Automatic (variable gear ratios) | 43 MPG | 40 MPG | 41 MPG | — | $1,500 / yr |
| Fusion Energi Plug-in Hybrid Plug-in Hybrid | 2L 4-Cyl | Front-Wheel Drive | Automatic (variable gear ratios) | 109 MPGe (43 MPG) | 97 MPGe (40 MPG) | 103 MPGe (42 MPG) | 26 mi EV (610 mi total) | $1,450 / yr |
| Fusion Special Service PHEV Plug-in Hybrid | 2L 4-Cyl | Front-Wheel Drive | Automatic (variable gear ratios) | 106 MPGe (43 MPG) | 97 MPGe (40 MPG) | 102 MPGe (42 MPG) | 26 mi EV (610 mi total) | $1,450 / yr |
Data Boundary Note: EPA specifications are shown by certified vehicle configuration. NHTSA complaints and recall totals are recorded at the model-year level across all configurations.
Electric Range & Charging: The 2020 Ford Fusion provides an official EPA-rated driving range of up to 26 miles on a single battery charge.
| Tested Drivetrain / Cab Variant | Overall Rating | Frontal Crash | Side Crash | Rollover Rating | Rollover Risk |
| 4 DR FWD | | | | | 10.9% |
| 4 DR AWD | | | | | 10.9% |
Active Driver Assistance Systems (NHTSA Recorded): Forward Collision Warning (FCW) is documented as Standard and Lane Departure Warning (LDW) is documented as Standard in official NHTSA records for tested 2020 Ford Fusion models.
View complete 2020 Ford Fusion crash test & safety breakdown →
Top Reported Problem Categories
Ranked by total consumer complaint submissions recorded by NHTSA
Data Attribution & Context: Complaints are self-reported by vehicle owners to NHTSA and represent unverified consumer submissions. Complaint volume does not equal a statistically controlled failure rate and is not adjusted for total vehicles sold or cumulative mileage driven.
View all 2020 Ford Fusion problems & component breakdown (59 categories) →
Affected Component: EQUIPMENT:ELECTRICAL:ENGINE BLOCK HEATER
Defect Summary: Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles. The engine block heater may crack and develop a coolant leak, causing it to short circuit when the block heater is plugged in.
Free Manufacturer Remedy: Owners are advised not to plug in their block heater until the vehicle is remedied. Dealers will replace the block heater, free of charge. Owners will also have a alternative option to replace engine block heater element with a threaded blanking plug, and remove the block heater electrical cord. Interim letters, notifying owners of the safety risk, were mailed December 3, 2025. Additional letters will be sent once the final remedy is available, anticipated September 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SA4. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on October 15, 2025.
Affected Component: BACK OVER PREVENTION:SOFTWARE
Defect Summary: Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2024 Bronco Sport, and 2022-2024 Maverick vehicles. A software error may cause the rearview camera to display a blank image, or the image may remain on the display after the backing event has ended.
Free Manufacturer Remedy: Dealers will update the rearview camera software, free of charge. Owner notification letters were mailed September 4, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S72.
Affected Component: ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM)
Defect Summary: Ford Motor Company (Ford) is recalling certain 2019-2020 Fusion PHEV vehicles. The battery energy control module (BECM) may become damaged due to excessive voltage and current flow.
Free Manufacturer Remedy: Owners are advised not to charge their vehicles until the remedy is completed. Dealers will replace the battery and update the BECM software for free, or Ford will repurchase the vehicle. If your vehicle is currently operating normally, Ford has authorized dealers to replace the fuse block and a software update as an interim repair before the availability of remedy parts for the final repair. This repair will be free of charge (parts and labor). As an alternative remedy, Ford is offering a vehicle refund. Please see Ford's owner notification letter or contact Ford for full details. Owner notification letters were mailed May 15, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S33.
View all 2020 Ford Fusion recalls & campaign history (3 campaigns) →