2010 Ford Fusion Tires & Wheels Problems

The contact owns a 2010 Ford Fusion. The contact stated that while the vehicle was parked, the wheel studs on the front passenger’s wheel detached from the wheel. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for further assistance. The failure mileage was approximately 61,000.

Multiple wheel studs have snapped in half, almost losing my wheel completely. This happened on all 4 wheels.

This vehicle has had multiple incidents in which the wheel studs on the front wheels will break off while driving. The last time this occurred, I noticed that 3 of the 5 wheel studs on the right-front wheel were broken off. When this was discovered, I contacted a Ford dealer and they said that there was no recall for this issue and didn't have any idea on how this had occured. I then contacted the last shop that had worked on the vehicle. They confirmed that the lug nuts were tightened using a torque wrench at the proper specifications. I have replaced several wheel studs and lug nuts on this vehicle in the past after they were found to be missing. The vehicle exhibits no vibration or warning signs while driving. This could have resulted in the wheel falling off while driving without warning.

Took the Ford Fusion to the local Ford dealer to have the tires rotated. They said they could not remove the lug nuts as they have swelled. It is not possible to change a flat or rotate the tires.

While driving 45mph on a smooth road, the tire sidewall blew out. Tire torn in several places. No sign of any contributing damage that could have caused the problem, nor was there a pothole or road debris. Tires are from 2019, and had 25,000 miles of use.

Swollen or warped lug nuts.

MY FUSION WAS ON RECALL FOR THE LUG NUTS. I TOOK MY CAR IN FOR THE REPLACEMENT LUG NUTS. THE NEW LUG NUTS ARE NOT THE SAME SIZE. I FOUND THAT OUT BY ROTATING MY TIRES. THE LUG RANCH FROM MY CAR DOES NOT FIT PROPERLY. THE COVERING OVER THE LUG NUTS THAT SUPPORTS THE HUB CAPS STRIPPED WHEN TRYING TO LOOSEN THE BOLTS. A STANDARD FOUR WAY LUG WRENCH WOULD NOT FIT ALSO. I WAS FORTUNATE MY NEIGHBOR WAS HOME WHO HAD A AIR GUN. HE HAD TO USE A DIFFERENT SIZE SOCKET TO EVEN GET THEM LOOSE. THE LUG NUT COVERS ON THE LUG NUTS ARE A DIFFERENT SIZE THEN THE OLD RECALL ONES. I NEVER HAD A PROBLEM BEFORE REMOVING THE OLD ONES WITH THE LUG RANCH THAT WAS PROVIDED WITH MY CAR. IF I HAVE A FLAT WHILE DRIVING THEIRS NO WAY OF CHANGING THE FLAT UNLESS YOU HAVE AN AIR GUN AND A CERTAIN SIZE SOCKET. I HAVE A FRIEND WHO DRIVES A FORD FUSION THAT HAD A TIRE THAT NEEDED TO BE CHANGED. THEY RAN INTO THE SAME PROBLEM WITH THE NEW LUG NUTS. THEY HAD TO CALL A TIRE STORE TO COME OUT TO THEIR HOME WITH AN AIR WRENCH AND A CERTAIN SIZE SOCKET TO REMOVE THE LUG NUTS. FORD MOTOR COMPANY NEEDS TO ADDRESS THIS PROBLEM. WHICH I DOUBT THEY WILL. THEY HAVEN'T REPLACE THE HCU YET ON MY CAR THAT I RECEIVED A RECALL ON A YEAR AGO. WHICH ENDING UP CAUSING ME TO WRECK THE CAR WHEN MY BRAKES FAILED AND CAUSING DAMAGES TO MY CAR.

OUR CAR HAS EXPERIENCED THREE BROKEN WHEEL STUDS TO DATE. A RECALL HAS BEEN ISSUED FOR THIS SAFETY DEFECT FOR THIS MODEL AND YEAR OF VEHICLE. THE DEALER AND THE MANUFACTURER STATE OUR CAR IS NOT COVERED FOR THIS MANUFACTURING DEFECT BECAUSE OF THE VIN NUMBER. WE HAVE PAID THE DEALER FOR THESE REPAIRS. BUT THE SAFETY DEFECT IS NOT A DEFECT BECAUSE OF THE VIN NUMBER? THE BROKEN WHEEL STUDS ARE AWARE OF THE VIN NUMBER?

TL* THE CONTACT OWNS A 2010 FORD FUSION. WHILE THE VEHICLE WAS UNDERGOING A ROUTINE INSPECTION AT SUNNYVALE FORD (650 E EL CAMINO REAL, SUNNYVALE, CA 94087, (408) 215-9949), THE MECHANIC NOTICED THAT THE FRONT DRIVER'S SIDE WHEEL LUG NUT WAS FRACTURED AND THE WHEEL COULD NOT BE REMOVED. THE VEHICLE WAS REPAIRED. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 11V574000 (WHEELS). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND PROVIDED CASE NUMBER: 25152622. THE FAILURE MILEAGE WAS 118,000.

TL* THE CONTACT OWNS A 2010 FORD FUSION. THE CONTACT STATED THAT THE LUG NUTS WERE DIFFICULT TO REMOVE FROM THE VEHICLE WHILE ATTEMPTING TO CHANGE TIRES ON THE VEHICLE. THE CONTACT STATED THAT THE FAILURE WAS DUE TO THE TWO-PIECE LUG NUT FUSING TOGETHER. ADDITIONALLY, WHILE DRIVING, THE OUTER SHELL OF THE LUG NUTS DETACHED. THE CONTACT STATED THAT THE BRAKING DISTANCE WAS ALSO EXTENDED WHILE DEPRESSING THE BRAKE PEDAL. INDEPENDENCE FORD LOCATED AT 3101 COLUMBIA BLVD, BLOOMSBURG PA, 17815 AND MANUFACTURER WERE NOTIFIED OF THE FAILURE HOWEVER, NO ASSISTANCE WAS OFFERED. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE FAILURE MILEAGE WAS 115,000. *BF*JB

TL* THE CONTACT OWNS A 2010 FORD FUSION. THE CONTACT STATED THAT THE LUG NUTS ON THE WHEELS WERE LOOSE AND WOULD NOT TIGHTEN. THE VEHICLE DISPLAYED THE SAME SYMPTOMS AS LISTED IN NHTSA CAMPAIGN NUMBER: 11V570000 (WHEELS). THE VEHICLE WAS TAKEN TO PRICE FORD OF TURLOCK (5200 N GOLDEN STATE BLVD, TURLOCK, CA 95382, (209) 669-5200), BUT NO ASSISTANCE WAS PROVIDED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED AND STATED THAT THEY WOULD NOT SERVICE THE VEHICLE. THE FAILURE MILEAGE WAS 108,000.

RECALL 11S23 DOES NOT FIX LUG STUD FRACTURE CAUSING WHEEL SEPARATION,RECALL WAS DONE YET AFTER DONE 4 OF 5 LUG STUDS BROKE OFF WHILE DRIVING RIGHT HAND FRONT AND 2 ON LEFT FRONT WHEEL . DRIVING STRAIGHT ON FREEWAY. COULD CAUSE LOSS OF LIFE

THE WHEEL LUG STUDS ARE BREAKING (INFERIOR METAL) RECALL 11S23 WAS COMPLETED BUT DOES NOT REPLACE ALL LUG STUDS JUST BROKEN ONES .YESTERDAY 4 OF 5 ON FRONT WHEEL BROKE IN HALF. RECALL SHOULD REPLACE ALL LUG STUDS.DRIVING ON FREEWAY 55 VIBRATION OCCURED STOPPED VEHICLE AND TOWED TO FORD. NOT COVERED BY RECALL

TL* THE CONTACT OWNS A 2010 FORD FUSION. THE CONTACT STATED THAT THE CHROME CAP COVER OVER THE LUG NUTS EXPANDED ON ALL FOUR TIRES. AS A RESULT, THE LUG NUTS WERE DAMAGED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE CONTACT WAS INFORMED THAT THE LUG NUTS NEEDED TO BE REPLACED. THE VEHICLE WAS CURRENTLY BEING REPAIRED. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR DIAGNOSTIC TESTING OR REPAIRS. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 83,000.

SEVEN WHEEL STUDS HAVE BROKEN OFF ON THE LEFT-HAND SIDE. SIX SINCE NOVEMBER, 2018. I DON'T KNOW WHEN THEY HAPPENED OR HOW, BUT NOTICED. ONE BROKE A LONG TIME AGO ON THE BACK LEFT WHEEL AND I DROVE ON IT FOR SEVERAL YEARS. I NOTICED AT THANKSGIVING TWO MORE ON THE FRONT LEFT WHEEL AND FIXED IT PROMPTLY, ONLY DRIVING TO PICK UP PARTS, REPLACING ALL FIVE ON THE FRONT TIRE AND THE BROKEN ONE OF THE BACK TIRE. IN JANUARY 2019, I NOTICED TWO MORE ON THE BACK WHEEL SHEARED OFF AND REPLACED ALL FIVE. IN APRIL 2019, I NOTICED TWO MORE ON THE BACK WHEEL SHEARED OFF AND REPLACED THOSE TWO. AT THIS POINT, I AM SHOPPING FOR A NEW CAR, BUT WANTED TO RAISE THE ALARM THAT THERE COULD BE SOMETHING GOING ON WITH THIS VEHICLE. I HAVE 190,000 MILES ON IT AND THE HUBCAPS (WHICH ARE KNOWN TO FALL OFF ON THIS VEHICLE) HAVE FALLEN OFF ON THREE OF THE FOUR WHEELS, INCLUDING THE TWO THAT HAVE HAD PROBLEMS.

PRIMEWELL VALERA TOURING DEVELOPED CRACKS IN THE SIDEWALL AND LOST AIR AT HIGHWAY SPEED. I FOUND OUT THAT THERE IS A RECALL FOR THESE TIRES. I AM TRYING TO GET THIS RECTIFIED WITH THE TIRE DISTRIBUTOR, BUT AT THIS POINT NO LUCK.

ABS MODULE SEEMS TO CAUSE RANDOM LOSS OF BRAKING -- VEHICLE STARTS BRAKING NORMALLY, THEN SUDDEN LOSS OF HYDRAULIC AND PEDAL GOES ALMOST TO FLOOR BEFORE SOME BRAKING RESUMES. IT'S A RELATIVELY INFREQUENT PROBLEM ( FOUR TIMES IN 6 MONTHS) WITH NO APPARENT TRIGGER, AND HAS HAPPENED WHEN PULLING STRAIGHT INTO A PARKING SPOT, STOPING FOR A STOPLIGHT, AND TURNING OFF OF A FREEWAY ONTO AN OFF-RAMP. WEATHER CONDITIONS DURING OCCURERENCES WERE DRY AND SUNNY TWICE, RAINING ONCE, AND OVERCAST AND ABOUT 50 DEG F ON THE MOST RECENT (OCT. 10, 2018) OCCASION. AN UNRELATED MATTER HAS TO DO WITH THEIR WHEEL LUG NUTS. THEY HAVE A TWO-PART CONSTRIUCTION, AND THE OUTER LAYER SWELLS SO THAT IT CANNOT BE SERVICED USING THE OEM TIRE CHANGING HARDWARE SUPPLIED WITH SPARE TIRE.

THERE HAS BEEN AN INVESTIGATION ON THIS COMPLAINT BUT IT NOT UNDER MY VIN NUMBER. MY CAR IS SHAKING CAUSING VIBRATION WHEN I'M DRIVING. THE TIRE SEEMS IF IT'S GOING TO FALL OFF THE CAR AS I'M DRIVING. THERE IS NO LIGHT INDICATING THERE IS SOMETHING WRONG. IT DOES NOT PICK UP SPEED I WOULD HAVE TO PUT MY FOOT ALL THE WAY TO THE FLOOR FOR IT TO REALLY GO ANYWHERE. I'M ON THE HIGHWAY EVERYDAY GOING TO WORK. I HOPE ONE OF THESE DAYS NOTHING HAPPENS TO ME OR MY FAMILY BECAUSE FORD WON'T JUST TAKE A LOOK AT THE CAR WHEN I'M CALLING THEM TELLING THEM THAT IT'S THE SAME PROBLEM THE RECALL EXPLAINS WHAT THE PROBLEMS ARE. RECALL #11V57400

LUGS NUTS WILL NOT COME OFF

COMPLAINT INVOLVING FORD FUSION TIRE BOLTS AND LUG NUTS (2010 MODEL). THIS IS THE SECOND TIME THE TIRE BOLTS BREAK (3 ON THE FRONT RIGHT SIDE AND 2 ON THE FRONT LEFT SIDE). THE VEHICLE FRONT TIRE BOLTS AND LUG NUTS WERE FIXED BY THE ORIGINAL FORD DEALER FOR THE A RECALL FOR THIS SAME EXACT ISSUE RIGHT AFTER WE PURCHASED THIS CAR IN 2010. WE'VE RECENTLY NOTICED A DIFFERENCE DRIVING (BOTH CITY AND HIGHWAY) AND TOOK IT IN FOR NORMAL MAINTENANCE AND THE EXACT SAME ISSUE HAS AROSE AGAIN IN THE EXACT SAME LOCATION. FORD DEALERSHIP DOESN'T HAVE ANY ADDITIONAL RECALL ON THIS SAME ISSUE, HOWEVER WE'VE READ THAT THERE IS A LAWSUIT IN MI REGARDING SWOLLEN LUG NUTS AND WONDER IF THIS IS RELATED. FURTHER DOCUMENTATION WILL BE COLLECTED ONCE OUR REPAIR IS PAID FOR.