2008 Ford Fusion Body & Structure Problems

Door handle is stuck/broken. Door cannot open from the inside or outside. Passengers are stuck in car.

ON DECEMBER 27TH 2019. MY DAUGHTER SLIDE INTO THE BACK OF ANOTHER CAR AND SHE COMPLAINED THE BREAKS WERE TAKING TO LONG TO COME TO A COMPLETE STOP. THE CAR WAS TOTALED AND ON JANUARY 23RD, 2020 WE RECEIVED SAFETY RECALL NOTICE 19S54/NHTSA RECALL 19V-904. HAD WE RECEIVED THIS NOTICE BEFORE 12/27/19 WE BELIEVE REPAIRS WOULD HAVE PREVENTED THE ACCIDENT AND THE CAR WOULD NOT HAVE BEEN SOLD FOR PARTS.

INTERIOR DOOR HANDLES ARE VERY WEAK AND BROKE. DOOR BECAME INOPERABLE FROM THE INSIDE. THE ONLY WAY TO OPEN THE DOOR WAS TO TURN THE IGNITION ON, ROLL DOWN THE WINDOW, AND THEN RELEASE THE EXTERIOR HANDLE. IT WOULD HAVE BEEN FATAL IF AN EMERGENCY EXIT WAS NEEDED.

THE DASH IS POPPING UP AROUND THE PASSENGER AIRBAG! FORD REFUSES TO DO ANYTHING ABOUT IT. THE INTERNET IS FULL OF COMPLAINTS ABOUT THIS.

HAD SEVERAL INCIDENTS WITH MY BRAKES NOT WORKING PROPERLY AFTER ABS GOING ON BY HITTIN MY BRAKES ON A BUMPY ROAD OR UNEVEN GRAVEL AND IN RAINY WEATHER, MY BRAKES WENT SOFT AND LOW AND I WOULD HAVE TO PRESS THE BRAKES ALL THE WAY DOWN TO THE GROUND FOR MY VEHICLE TO STOP. AFTER PUMPING THE BRAKES AND STOPPING A LOT OF TIMES THE BRAKES WOULD GO SOMEWHAT BACK TO NORMAL, RECENTLY I PRESSED MY BRAKES IN UNEVEN GRAVEL AND I ALMOST RAN INTO A CONSTRUCTION POST BECAUSE MY BRAKES GAVE OUT ON ME AND WENT SOFT AND LOW, SO I HAD TO TURN MY VEHICLE TO PREVENT ME FROM CRASHING, MY BRAKES HAVE BEEN LOW AND SOFT EVER SINCE AND I DROVE MY VEHICLE SEVERAL TIMES AFTER THAT INCIDENT AND MY BRAKES HAVE NOT RETURNED BACK TO NORMAL, IM TRYING TO FIGURE OUT THIS ISSUE AND BELIEVE IT'S EXTREMELY DANGEROUS, I TAKE CARE OF MY VEHICLE IT LOOKS BRAND NEW STILL AND I ALWAYS TAKE CARE OF IT, I JUST DON'T UNDERSTAND WHY THIS IS HAPPENING AND ALMOST CAUSED ME TO CRASH INTO A CONSTRUCTION POST, I BELIEVE FROM RESEARCHING THAT OTHERS WITH THE 2008 FORD FUSIONS ARE EXPERIENCING THE SAME PROBLEMS.

TL* THE CONTACT OWNS A 2008 FORD FUSION. WHILE DRIVING APPROXIMATELY 55 MPH, THE CHECK ENGINE SERVICE INDICATOR ILLUMINATED AND A STRONG ODOR WAS DETECTED FROM THE ENGINE. THE CONTACT ALSO MENTIONED THAT THE DRIVER SIDE DOOR WAS HARD TO OPEN UPON EXITING THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VIN WAS INVALID. THE FAILURE MILEAGE WAS APPROXIMATELY 71,000.

ON MY FORD FUSION DRIVERS DOOR THE RELEASE MECHANISM IS BROKEN. I CAN NOT EXIT THE CAR FROM THIS DOOR AND IN THE EVENT OF AN EMERGENCY THE ESCAPE FROM THE VEHICLE WOULD BE GREATLY HINDERED. I WOULD HAVE TO EXIT THROUGH THE PASSENGER DOOR OR THROUGH THE WINDOW. RESEARCH (YOUTUBE VIDEOS)SHOWS THIS PLASTIC PART BREAKS FREQUENTLY.

I HAD UNLOCKED MY DOOR VIA THE AUTOMATIC LOCK SWITCH TO EXIT THE VEHICLE. I WENT TO PULL THE INDOOR DRIVER'S SIDE LATCH TO EXIT WHEN THE AUTOMATIC LOCKS BEGAN LOCKING AND UNLOCKING ON THEIR OWN, SO I DISENGAGED THE LATCH. THE LATCH THEN BROKE/POPPED OUT WITHOUT ME TOUCHING IT. I CAN NO LONGER EXIT OUT OF THE DRIVER'S SIDE DOOR WITHOUT ROLLING DOWN THE AUTOMATIC WINDOWS AND OPENING THE DOOR FROM THE OUTSIDE HANDLE. MY VEHICLE WAS TURNED OFF WITH THE KEYS OUT OF THE IGNITION WHEN THIS TOOK PLACE.

DRIVER DOOR HANDLE WILL NOT OPEN FROM INSIDE. MUST ROLL DOWN POWER WINDOW REQUIRES IGNITION ON OR ENGINE RUNNING TO OPEN DOOR FROM OUTSIDE DOOR HANDLE. DRIVER DOOR WILL NOT LOCK. (NO SECURITY OR THEFT PROTECTION) EGRESS FROM CAR IMPOSSIBLE FROM INSIDE DRIVER SIDE. EXIT VIA PASSENGER DOOR BLOCKED BY CENTER CONSOLE. LOSS OF IGNITION LEAVES DRIVER STRAANDED INSIDE VEHICLE.

THE DASH AROUND THE PASSENGER SIDE AIRBAG AS WELL AS THE VENT ALONGSIDE THE WINDSHIELD AND THE SWITCH THAT TURNS ON AND OFF THE LIGHTS AS WELL AS DIMMING THE LIGHTS AND A TRUNK RELEASE HATCH IS BUCKLING UP AND SEPARATING FROM EACH OTHER THIS HAS OCCURRED DUE TO JUST NORMAL WEAR AND TEAR AND DRIVING SITUATIONS AND NORMAL TEMPERATURE FLUCTUATIONS

TL* THE CONTACT OWNS A 2008 FORD FUSION. WHEN ATTEMPTING TO EXIT THE VEHICLE, THE DOOR HANDLE FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN AND FAILURE MILEAGE WERE UNKNOWN.

DRIVER'S INTERIOR DOOR LATCH BROKE. THIS IS A COMMON PROBLEM ON THIS CAR FROM MY RESEARCH. THIS IS ALSO A SAFETY ISSUE. THE ONLY WAY OUT OF THE CAR IS BY LOWERING THE WINDOW AND OPENING THE DOOR FROM THE OUTSIDE. IN THE EVENT OF AN EMERGENCY, THIS MAY NOT BE FEASIBLE. THE 2013 FUSION HAS THE SAME PROBLEM AND THIS WAS A RECALL. WHY NOT ON THE EARLIER FUSION. REPAIRS COST OWNERS OVER $300.

THE CHROME ON THE INTERIOR DRIVER DOOR HANDLE IS PEELING AWAY ON TOP CREATING A RAZOR SHARP EDGE. THIS SLICED MY FINGER. *TR

PASSENGER DOOR LATCH/LOCK BROKE, UNABLE TO OPEN DOOR FROM THE INSIDE. I HAVE OWN THIS FUSION SINCE 2008 THIS IS THE THIRD TIME A DOOR LATCH/LOCK HAS BROKEN. THE PREVIOUS TWO TIMES HAVE BEEN ON THE DRIVER SIDE, FIRST TIME MILEAGE WAS AROUND 40,000 SECOND TIME WAS AROUND 80,000. BELIEVE THIS CAN BE A SAFETY ISSUE IS THE CAR IS INTO A CAR ACCIDENT OR IS FORCE INTO THE WATER THE DRIVER OR PASSENGER WOULD BE UNABLE TO ESCAPE THE CAR. *TR

DRIVER'S SIDE INTERIOR DOOR HANDLE FAILED AND WOULD NOT OPEN DOOR. HAD TO POWER WINDOW DOWN AND OPEN FROM EXTERIOR. WOULD BE A SAFETY ISSUE IF PERSON NEEDED TO EXIT VEHICLE QUICKLY. NOTICED THERE WERE SEVERAL COMPLAINTS UNDER BOTH "LATCHES/LOCKS" AND "STRUCTURE" THAT WERE THE SAME OR SIMILAR. I DIDN'T CHECK OTHER MODEL YEARS, HOWEVER SINCE THE FAILED PART FITS SEVERAL OTHER MODEL YEARS I WOULD THINK THERE WOULD HAVE BEEN MANY OTHER COMPLAINTS ON THIS ISSUE. *TR

DRIVER'S DOOR ON LEFT SIDE OF VEHICLE, DOOR LOCK AND UNLOCK LATCH BROKE, RENDERING DOOR INOPERATIVE, CAN ONLY ENTER AND EXIT VEHICLE BY USING OUTSIDE DOOR LATCH (ROLL DOWN WINDOW, REACH YOUR ARM OUT, PULL LATCH TO OPEN, ROLL WINDOW BACK UP AND EXIT VEHICLE, BUT WILL NOT LOCK) AND DOOR WILL NO LONGER LOCK, REMAINS UNLOCKED AT ALL TIMES, PART NUMBER 6E5Z5422601A IS THE FAULTY PART PLASTIC BREAKS JAMMING THE UNLOCK LATCH FROM MOVING. THE CHROME PLASTIC OF THE HANDLE IS NICE, BUT CLEARLY A METAL COMPOSITION SHOULD HAVE BEEN USED IN THE DESIGN INSTEAD OF PLASTIC, AFTER RESEARCHING ON THE WEB APPEARS TO BE SEVERAL CONSUMERS WITH THE SAME ISSUE. PART PRICES RANGE FROM $70.00 - $192.00 DEPENDING ON THE SELLER / BUSINESS, SUCH AND ISSUE THAT EVEN THE CHINESE ARE MAKING MONEY BY MANUFACTURING THE PART. SAFETY CONCERNS ARE EXITING THE VEHICLE IN AN ACCIDENT, THE DRIVER IS TRAPPED, HAVE NOT SEEN ANYTHING ON WEB OF ACCIDENT DEATHS DUE TO FAULT, BUT I'M SURE IT'S COMING. *TR

I CANNOT EXIT THE VEHICLE DRIVER'S SIDE USING THE INSIDE DOOR HANDLE. I HAVE TO ROLL THE WINDOW DOWN AND THEN OPEN THE DOOR WITH THE OUTSIDE HANDLE. THIS PROBLEM HAS OCCURRED ON ITS OWN. THERE WAS NO ACCIDENT OR ANYTHING LIKE THAT. IT JUST STOPPED WORKING ONE DAY. I HAVE BEEN ON LINE AND OTHER FUSION OWNERS ARE EXPERIENCING THE SAME PROBLEM AND HAVE CONTACTED FORD AS I HAVE AND FORD WON'T DO ANYTHING ABOUT IT. I FEEL THAT THIS IS A SERIOUS PROBLEM IN THAT, IF I WERE IN AN ACCIDENT, AND THE BATTERY CABLE GOT CUT SO THERE WAS NO POWER TO THE VEHICLE, I WOULD HAVE TO CLIMB OVER THE CENTER COUNSEL TO EXIT THE VEHICLE THROUGH THE PASSENGER DOOR IF IT DIDN'T BECOME INOPERABLE IN THE ACCIDENT. I WOULD ASSUME THAT THIS PROBLEM COULD ALSO OCCUR WITH THE PASSENGER DOOR AS WELL SO I'M NOT FEELING ALL THAT SAFE AT THE MOMENT. I'M GOING TO SPEND THE MONEY TO GET IT REPAIRED, BUT IN TODAY'S ECONOMY, SOME PEOPLE COULDN'T AFFORD THAT. *TR

TL* THE CONTACT OWNS A 2008 FORD FUSION. THE CONTACT STATED THAT THE PASSENGER'S SIDE DASHBOARD MATERIAL WAS BULGING WHERE THE AIR BAG WAS LOCATED. THE FAILURE WAS NOT DIAGNOSED BY A DEALER OR AN INDEPENDENT MECHANIC AND THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 70,000.

TL* THE CONTACT OWNS A 2008 FORD FUSION. THE CONTACT STATED THAT THE PASSENGER'S SIDE DASHBOARD WAS SEPARATING WHICH COULD POSSIBLY EXPOSE THE AIR BAG. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE ENTIRE DASHBOARD NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 55,000.

MY WIFE PARKED HER 2008 FORD FUSION IN OUR GARAGE AND AS SHE TRIED TO EXIT THE VEHICLE THE INSIDE LEFT DRIVER'S DOOR HANDLE WOULD NOT OPEN THE DOOR. SHE TRIED TO OPEN THE DOOR SEVERAL TIMES AND ALMOST PANICKED. SHE WAS TRAPPED INSIDE. FORTUNATELY HER CAR IS EQUIPPED WITH A MICROSOFT SYNC SYSTEM AND SHE WAS ABLE TO CALL ME INSIDE THE HOUSE FROM THE GARAGE. I CAME TO HER AND WAS UNABLE TO OPEN THE DOOR FROM THE OUTSIDE BECAUSE THE DRIVER'S DOOR LOCK DID NOT AUTOMATICALLY DISENGAGE WHEN SHE SHUT THE KEY OFF. SHE ROLLED DOWN THE WINDOW AND I REACHED INSIDE TO TEST THE INNER DOOR HANDLE AND LOCK. THE LOCK WAS STUCK AND THE HANDLE JUST MOVED FREELY BACK AND FORTH AS I PULLED ON IT. FINALLY, AFTER WIGGLING THE INNER LOCK BACK AND FORTH MANY TIMES I WAS ABLE TO DISENGAGE THE DOOR LOCK. I THEN COULD OPEN THE DOOR BY USING THE OUTSIDE DRIVERS DOOR HANDLE. SHE GOT OUT OF THE VEHICLE AND I PROCEEDED TO EXAMINE THE DOOR MECHANISM. I REMOVED THE COVER PLATE AND SAW THAT THE PLASTIC ACTUATOR ARM ON THE INNER END OF THE DOOR HANDLE HAD BROKEN IN TWO AND PART OF IT HAD GOTTEN CAUGHT UP IN THE LOCKING MECHANISM. SO I CAME INSIDE AND SEARCHED ON-LINE TO BUY A NEW REPLACEMENT HANDLE. DURING MY SEARCH I DISCOVERED THAT PEOPLE ALL ACROSS THE UNITED STATES ARE CLAIMING THAT THIS SEEMS TO BE A COMMON PROBLEM WITH SEVERAL DIFFERENT YEARS OF FORD FUSIONS. FORTUNATELY FOR MY WIFE SHE WASN'T INVOLVED IN A MAJOR ACCIDENT AND COULDN'T GET OUT OF THE VEHICLE WHEN THE MALFUNCTION OCCURRED BUT I BELIEVE IT'S JUST A MATTER OF TIME BEFORE SOMETHING TRAGIC HAPPENS AS A RESULT OF THIS POTENTIALLY DEFECTIVE PART. I FEEL THAT EVEN THOUGHT THE VEHICLE HAS HIGH MILEAGE THIS PART SHOULD NEVER FAIL. THIS ACTUATOR ARM IS JUST A VERY, VERY, THIN PIECE OF PLASTIC AND I SUSPECT THAT ALL FOUR INNER DOOR HANDLES OF THE FORD FUSION ARE OF THE SAME DESIGN. *TR