23S33 – PHEV Battery Cell Degradation – 2019-2020 Ford Fusion PHEV

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-440 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Ford Motor Company Submission Date : JUN 23, 2023 NHTSA Recall No. : 23V-440 Manufacturer Recall No. : 23S33 Manufacturer Information : Manufacturer Name : Ford Motor Company Address : 330 Town Center Drive Suite 500 Dearborn MI 48126-2738 Company phone : 1-866-436-7332 Population : Number of potentially involved : 14,452 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2019-2020 Ford Fusion Vehicle Type : LIGHT VEHICLES Body Style : Power Train : NR Descriptive Information : Affected vehicles were produced between 12/06/17 and 07/27/20 and are equipped with the 2.0L PHEV drivetrain and 30Ah high voltage batteries. These vehicles are not produced in VIN order. Information as to the applicability of this action to specific vehicles can best be obtained by either calling Ford’s toll-free line (1-866-436-7332) or by contacting a local Ford or Lincoln dealer who can obtain specific information regarding the vehicles from the Ford On-line Automotive Service Information System (OASIS) database. Production Dates : DEC 06, 2017 – JUL 27, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Current Interrupt Device (CID) activation in a high voltage battery cell can result in excess voltage and current flow through the Battery Energy Control Module (BECM), which can cause damage to the BECM. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A damaged BECM caused by excess voltage and current flow can result in a loss of motive power which increases the risk of a crash, or a localized fire around the BECM, which increases the risk of injury. Description of the Cause : The root cause of the CID activation is currently unknown and under investigation. Part 573 Safety Recall Report 23V-440 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : Drivers may receive a stop safely now message prior to losing motive power. Involved Components : Component Name 1 : Not Reported Component Description : Not Reported Component Part Number : Not Reported Supplier Identification : Component Manufacturer Name : Not Reported Address : Not Reported Not Reported Not Reported – Country : NR Chronology : On July 17, 2022, Ford’s Trend and Early Warning Support (TEWS) team informed the Critical Concern Review Group (CCRG) of five reports of fire allegations that occurred in the trunk area on 2019 Fusion PHEV vehicles in North America equipped with 30Ah high voltage batteries. All of the incidents occurred between March and May 2022. The fires occurred while the vehicles were at dealerships during a replacement Battery Energy Control Module (BECM) service to remedy one or more voltage sense Diagnostic Trouble Codes (DTCs), a check engine light, no start, or loss of motive power concern. Analysis of the vehicles by Ford’s High Voltage Battery Systems Team identified the fires originated in the BECM. The high voltage batteries were sent to the supplier for analysis. The supplier confirmed the Current Interrupt Device (CID) was activated in high voltage battery cells from the suspect units, but the root cause of the CID activation is unknown. On August 16, 2022, Ford’s CCRG placed the investigation on monitor based on the rate and severity of the concern. On February 8, 2023, a Technical Service Bulletin (TSB) was published providing direction to replace the high voltage battery if vehicles came in for service with one or more voltage sense DTCs rather than only replacing the BECM. Part 573 Safety Recall Report 23V-440 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 On May 2, 2023, the issue returned to CCRG for review. Two additional fires occurred during the monitor period, both while a customer was driving the vehicle. At that time, the CCRG was aware of seven fires and 270 warranty claims resulting in a loss of motive power as a result of this concern. On June 16, 2023, Ford’s Field Review Committee reviewed the concern and approved a field action. Ford is not aware of any accidents or injuries as a result of this concern. Description of Remedy : Description of Remedy Program : Owners of vehicles will be notified by mail to refrain from charging their vehicles to maintain a lower charge level in the high voltage battery, reducing the risk of a loss of motive power and vehicle fire until a remedy is available. Owners will also be informed that Ford’s investigation is ongoing and that they will be contacted when further information is available. Ford provided the general reimbursement plan for the cost of remedies paid for by vehicle owners prior to notification of a safety recall in May 2023. Ford will forward a copy of the notification letters to dealers to the agency when available. How Remedy Component Differs from Recalled Component : Not applicable at this time. Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Notification to dealers is expected to occur on June 27, 2023. Mailing of owner notification letters is expected to begin July 10, 2023 and is expected to be completed by July 28, 2023. Planned Dealer Notification Date : JUN 27, 2023 – JUN 27, 2023 Planned Owner Notification Date : JUL 10, 2023 – JUL 28, 2023 * NR – Not Reported

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Ó Copyright 2023 Ford Motor Company Stacy L. Balzer Ford Motor Company Operating Director P. O. Box 1904 Service Engineering Operations Dearborn, Michigan 48121 Ford Customer Service Division June 27, 2023 TO: All U.S. Ford and Lincoln Dealers SUBJECT: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 23S33 Certain 2019-2020 Model Year Fusion Energi PHEV vehicles PHEV Battery Cell Degradation AFFECTED VEHICLES Vehicle Model Year Assembly Plant Build Dates Fusion Energi 2019-2020 Hermosillo December 6, 2017 through July 27, 2020 U.S. population of affected vehicles: 14,452. Affected vehicles are identified in OASIS and FSA VIN Lists. REASON FOR THIS SAFETY RECALL In some of the affected vehicles, Current Interrupt Device (CID) activation in a high voltage battery cell can result in excess voltage and current flow through the Battery Energy Control Module (BECM), which can cause damage to the BECM. Excess voltage and current flow through the BECM can result in a loss of motive power which increases the risk of a crash, or a vehicle fire in the trunk area which increases the risk of injury. Owners of vehicles will be notified by mail to refrain from charging their vehicles to maintain a lower charge level in the high voltage battery, reducing the risk of a loss of motive power or vehicle fire until a remedy is available. SERVICE ACTION DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this safety recall. More information will be provided to dealers in October 2023. IMPORTANT: Dealers should open a Repair Order (RO) only when a full dealer bulletin is published or to submit a claim for refunds, pickup and delivery, towing or rental. Ó Copyright 2023 Ford Motor Company OWNER NOTIFICATION MAILING SCHEDULE No Part Owner letters are expected to be mailed the week of July 10, 2023. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter. PLEASE NOTE: Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $26,315 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. ATTACHMENTS Attachment I: Administrative Information Attachment II: Labor Allowances Owner Notification Letters QUESTIONS & ASSISTANCE For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician System (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab. Sincerely, Stacy L. Balzer Ó Copyright 2023 Ford Motor Company ATTACHMENT I Page 1 of 2 NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Advance Notice –Safety Recall 23S33 Certain 2019-2020 Model Year Fusion Energi PHEV vehicles PHEV Battery Cell Degradation MOBILE SERVICE REPAIR ASSESSMENT LEVEL – Not a Mobile Service Repair OASIS ACTIVATION OASIS will be activated on June 27, 2023. FSA VIN LISTS ACTIVATION FSA VIN Lists will be available through https://web.fsavinlists.dealerconnection.com by June 27, 2023. Owner names and addresses will be available by August 4, 2023. NOTE: Your FSA VIN Lists may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall. SOLD VEHICLES • Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealers for an appointment to have their vehicles remedied after a solution has been announced. STOCK VEHICLES • Correct all affected units in your new vehicle inventory before delivery. • Use OASIS to identify any affected vehicles in your used vehicle inventory. DEALER-OPERATED RENTAL VEHICLES The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting, or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice. BRANDED / SALVAGED TITLE VEHICLES Affected title-branded and salvaged vehicles are eligible for this recall. OWNER REFUNDS • This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. • Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed before the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121- 6251. • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. • Refunds will only be provided for the cost associated with high-voltage battery replacement. Ó Copyright 2023 Ford Motor Company ATTACHMENT I Page 2 of 2 NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Advance Notice –Safety Recall 23S33 Certain 2019-2020 Model Year Fusion Energi PHEV vehicles PHEV Battery Cell Degradation RENTAL VEHICLES • Ford has not issued instructions to stop driving vehicles under this safety recall. • If the CID has activated and a replacement high voltage battery is not available submit a request to the SSSC under FSA 23A06 using contact-type APPROVAL REQUEST for consideration. Follow Extended Service Plan (ESP) guidelines for dollar amounts. TOWING If towing is required, dealers are authorized to claim up to a maximum value of $250 to provide towing services for this program. PICK-UP AND DELIVERY- Participating Dealers Dealers participating in the Remote Experience Program: • Refer to EFC12071, 2023 Remote Experience Program, Pickup & Delivery (PDL) Offset section for additional details. CLAIMS PREPARATION AND SUBMISSION • Rentals: Submit a request to SSSC under FSA 23A06 using contact-type APPROVAL REQUEST for consideration. Follow Extended Service Plan (ESP) guidelines for dollar amounts. • Refunds: Submit refunds on a separate repair line. – Program Code: 23S33 – Misc. Expense: ADMIN – Misc. Expense: REFUND – Misc. Expense: 0.2 Hrs. o Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. • Provision for Towing: Dealers are authorized to claim up to a maximum value of $250 to provide towing services for completing this program. Submit on the same line as the repair. o Program Code: 23S33 o Misc. Expense: OTHER o Misc. Expense: Claim up to $250.00 Ó Copyright 2023 Ford Motor Company ATTACHMENT II Page 1 of 1 NEW VEHICLE DEMONSTRATION / DELIVERY HOLD Advance Notice –Safety Recall 23S33 Certain 2019-2020 Model Year Fusion Energi PHEV vehicles PHEV Battery Cell Degradation LABOR ALLOWANCES Labor allowances will be released when a solution is reached.

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