2020 Ford Fusion Problems

What owners report

Owners of this model year most often describe drivetrain and engine problems: a cracked flex plate that produces a rattle or knock near the transmission bellhousing, and coolant intrusion into the cylinders that leads to engine replacement. Transmission slipping, delayed engagement and a gear shifter that jumps back to park also appear repeatedly, usually at moderate to high mileage. Electrical complaints, by contrast, cluster at very low mileage and concern battery drain and infotainment or camera behavior.

1. 1
   Transmission and drivetrain

   Cracked flex plate rattle or knock

   • 29 complaints (16%)
   • median 90,374 mi at 5.0 yrs old (16 state mileage)
   • filed 2022–2026

   Owners describe a rattling or knocking sound from the engine compartment or near where the transmission meets the engine, often most noticeable at idle, on start-up, or with the air conditioning running. Some say the vehicle hesitates, loses power or will not restart. Dealers and independent shops diagnosed a cracked flex plate (flywheel) and quoted replacement, sometimes together with the torque converter, pump and seals; several owners mention a customer satisfaction program for this part and report being told their vehicle was outside it or that it had expired. Reported from about 25,000 to 150,000 miles, with many between 60,000 and 105,000 miles.

   1 related service bulletin

   What to check: Listen for a rattle at idle and on cold start with the hood open, and ask whether the flex plate, torque converter or related hardware has already been replaced. Ask for service records showing any customer satisfaction program work.

   2 excerpts from owner complaints in NHTSA records

   “Flex plate is cracked , confirmed by bore scope dealership is quoting 14 business days to diagnose. It is known issue with this make, model, and year and CSP was issued for dealerships to fix but only select VIN numbers. This car is at 91000 miles and meets all criteria for the CSP 22N12. The car makes an ungodly rattling sound and if it fails could be very dangerous”

   NHTSA complaint #11610976, filed 2024-08

   “The contact owns a 2020 Ford Fusion. The contact stated that while operating the vehicle, there was a ticking and knocking sound coming from the engine compartment. The vehicle was taken to the local dealer. The cause of the issue was not yet determined. The manufacturer was not contacted. The failure mileage was 79,000.”

   NHTSA complaint #11625858, filed 2024-11, 79,000 miles
2. 2
   Engine

   Coolant intrusion causing engine failure

   • 20 complaints (11%)
   • median 79,563 mi at 5.7 yrs old (8 state mileage, few)
   • filed 2021–2026

   Complaints describe a check engine light, misfire, overheating, white smoke from the exhaust or engine bay, and in some cases the engine stalling or seizing. Shops diagnosed coolant leaking into one or more cylinders and told owners the engine or short block needed replacement. Several owners say the repair was not covered and that the manufacturer referred them to the NHTSA hotline. Mostly reported between roughly 65,000 and 112,000 miles, with one at about 40,000 miles.

   What to check: Check the coolant level and look for white residue or steam at the exhaust, and ask whether coolant intrusion or a head gasket repair has been done. A cooling system pressure test and a scan for stored misfire codes are reasonable before purchase.

   2 excerpts from owner complaints in NHTSA records

   “The contact owns a 2020 Ford Fusion. The contact stated that upon starting the vehicle, her husband noticed white smoke coming out of the mufflers. The vehicle was taken to the dealer, where it was diagnosed that the engine short block had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 111,000.”

   NHTSA complaint #11660649, filed 2025-05, 111,000 miles

   “The contact owns a 2020 Ford Fusion. The contact stated that the vehicle was started, there was a large amount of white smoke coming from the exhaust pipe, with the engine sputtering. The vehicle as taken to an independent mechanic and was diagnosed with engine block failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and a complaint was filed. The failure mileage was approximately 71,000.”

   NHTSA complaint #11666086, filed 2025-06, 71,000 miles
3. 3
   Transmission and drivetrain

   Transmission slipping, whine or shudder

   • 38 complaints (21%)
   • median 75,002 mi at 3.6 yrs old (13 state mileage)
   • filed 2020–2026

   Complaints describe rough or delayed shifting, a whining or clunking sound that changes with gear selection, shuddering, hesitation on acceleration and occasional loss of power. Some dealers flushed the fluid, which helped temporarily, while others told owners the transmission needed replacement; a few report repeated transmission work within the first several years of ownership. Broadly spread, from about 45,000 to over 120,000 miles, with many near 65,000 to 100,000 miles.

   1 related service bulletin

   What to check: Test drive at low and highway speeds and listen for whine or rattle that changes when shifting into park or neutral. Ask for transmission fluid service records and whether any repair or replacement has been done.

   2 excerpts from owner complaints in NHTSA records

   “The touchscreen display is not working. It turned completely black. I cannot change the radio station. I shut off my car and turned it back on and it is still not working had to hard reset the system car also shifts hard in and out of park and reverse, makes a clunking sound and shifts hard in first and second”

   NHTSA complaint #11383303, filed 2020-12, 17,500 miles

   “This makes the third time the transmission had to be redone and I have only 95.000 miles on it the first time was about 2months after I purchased the car brand new in December 2020 and each time the transmission gets repaired it cost more and more and they tell me that it need other stuff with it that needs to be replaced nothing in the dash showed failure to any thing”

   NHTSA complaint #11690227, filed 2025-09
4. 4
   Transmission and drivetrain

   Gear shifter jumps to park or won't engage

   • 37 complaints (20%)
   • median 75,002 mi at 3.6 yrs old (13 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2021–2026

   Owners report the rotary shifter returning to park on its own, failing to move into the intended gear, or the vehicle refusing to move after selecting drive or reverse. Some see a wrench or 'Transmission Not in Park' message. Dealers diagnosed a detached or broken shifter cable bushing and replaced it; some owners say the problem returned after repair. Reported from about 25,000 to 150,000 miles; several cases around 80,000 to 103,000 miles.

   What to check: Cycle the shifter through all positions several times and confirm the gear indicated on the cluster matches, and ask whether the shifter cable or bushing has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “The contact owns a 2020 Ford Fusion. The contact stated that while attempting to drive forward after reversing the vehicle, the vehicle failed to move. The wrench symbol displayed stating there was a system malfunction however, the contact was unsure of the system failure. The contact stated that the diagnostic App linked to the vehicle stated that there was power train malfunction causing reduced power. …”

   NHTSA complaint #11508861, filed 2023-02, 80,000 miles

   “The contact owns a 2020 Ford Fusion. The contact stated that while reversing from the residence, the vehicle suddenly stopped and shifted into park. The contact shifted to reverse, but the gear shifter independently shifted back to park. The contact stated that the vehicle failed to shift to the intended gear. The transmission shifter and the see the owner’s manual messages were displayed. There was a WRENCH symbol displayed. …”

   NHTSA complaint #11655381, filed 2025-04, 79,127 miles
5. 5
   Electrical system

   Battery drain and infotainment or camera glitches

   • 21 complaints (11%)
   • median 10,775 mi at 1.3 yrs old (6 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 2020–2026

   Owners report the battery draining quickly and needing repeated jump starts, even shortly after a new battery was installed. Others describe a touchscreen going black or unresponsive, the backup camera staying on while driving, and phone connectivity or app features failing to work. Dealers replaced sensors or modules and performed software updates in some cases. Electrical complaints in the sample are concentrated at very low mileage, mostly under about 30,000 miles and in the first year or two.

   Recall 25V4420004 related service bulletins

   What to check: Test the screen, backup camera and phone pairing, and check the battery age and any record of software updates; ask whether a battery drain or charging fault has been investigated.

   2 excerpts from owner complaints in NHTSA records

   “Battery drains very quickly and needs to be jump-started repeatedly, which has risks to safety and equipment. A new battery was installed earlier this month and it has already drained also. This is a fleet vehicle.”

   NHTSA complaint #11395771, filed 2021-02, 2,000 miles

   “The contact owns a 2020 Ford Fusion. The contact stated while driving 68 MPH, the vehicle started to stall. The vehicle was taken to the dealer and the contact was informed that the vehicle was not wired correctly. The vehicle was repaired but the failure reoccurred. The manufacturer was contacted but offered no assistance. The contact was referred to the NHTSA Hotline for assistance. The failure mileage was 30,000.”

   NHTSA complaint #11481989, filed 2022-08, 30,000 miles

Buying note. A pre-purchase inspection focused on the drivetrain is worthwhile here: listen for a flex plate rattle and check for coolant loss or white exhaust smoke, and get any transmission work history in writing. Confirming which open recalls and software updates have been completed on the specific vehicle is also a sensible step.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.