December 18, 2019 NHTSA CAMPAIGN NUMBER: 19V904000

ABS Valve May Remain Open after ABS Event

If the valves do not properly close, additional brake pedal travel may be required to stop the vehicle, increasing the risk of a crash.

 

NHTSA Campaign Number: 19V904

Manufacturer Ford Motor Company

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 600,166

 

Summary

Ford Motor Company (Ford) is recalling certain 2006-2010 Ford Fusion, Mercury Milan, Lincoln Zephyr and MKZ vehicles. The valves within the ABS Hydraulic Control Units (HCU) may react with brake fluids containing specific corrosion preventative additives. This reaction may cause the valves to not close properly.

 

Remedy

Ford will notify owners, and dealers will flush the brake system with DOT 4 fluid and install a new brake fluid reservoir cap. In addition, the HCU will be tested to detect a possible stuck valve condition, replacing the HCU as necessary. All services will be performed free of charge. Owners were notified of the safety risk with an interim letter on January 22, 2020. A second notice will be sent once parts are available, expected to be in the first quarter of 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 19S54.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Vehicle has a Recall

 

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September 28, 2020

TO: All U.S.Ford and Lincoln Dealers

SUBJECT: Advance Notice – Safety Recall 19S54 –Supplement #2
Certain 2006-2010 Model Year Fusion/Milan/MKZ/Zephyr Vehicles Equipped with Anti-Lock Brake Systems
DOT 3 Brake Fluid and Anti-Lock Brake System Function

 

AFFECTED VEHICLES

Vehicle	Model Year	Assembly Plant	Build Dates
Fusion/Milan/MKZ/ Zephyr	2006-2010	Hermosillo	February 22, 2006 through July 15, 2009

 

Affected vehicles are identified in OASIS and FSA VIN Lists.

 

New! REASON FOR THIS SUPPLEMENT

• This supplement is to update dealers, due to raw material constraints with suppliers, parts are expected to be available 1^st Quarter 2021.
• Dealers should continue to perform normal workshop manual diagnostics and repairs when a customer has a braking system concern or when maintenance is required.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, a chemical reaction between aged DOT 3 brake fluid and the zinc plating inside the Hydraulic Control Unit (HCU) may result in a gel formation. A normally closed valve may be stuck open, which may result in extended brake pedal travel. However, the condition does not result in a loss of braking function or loss of vehicle control, and vehicles can be safely brought to a controlled stop.

 

New! SERVICE ACTION

• This program is not intended to cover all brake system concerns on customer vehicles, normal workshop manual (WSM) diagnostics and related damage are not covered in this program.
• Preliminary feedback from our Customer Relationship Center (CRC), and Special Service Support Center (SSSC), indicates that dealers may be incorrectly advising customers to wait until parts are available before performing any necessary diagnostics for a myriad of brake concerns.
• If a customer with an affected vehicle arrives at your dealership with a brake concern and mentions FSA 19S54, dealers should review pre-existing brake concerns and recommend performing the applicable WSM diagnostics, starting in Section 206.
• Any existing diagnostic trouble codes (DTCs) should be properly diagnosed and resolved outside of this field service action. There are no DTCs associated with this concern, no DTCs are generated by the HCU when this concern occurs and resolution of DTCs cannot be claimed as part of this program or as related damage.
• HCUs will only be replaced with documented pass/does not pass IDS service function test (currently under development). We expect this failure rate to be less than 1% of the vehicle population.
• All vehicles will have the brake system flushed with DOT 4 brake fluid, new brake fluid reservoir caps with Dot-4 nomenclature and an updated Owner’s Guide insert.
• Parts considered normal maintenance will not be covered under this program and cannot be claimed as related damage.
• A complete Dealer Bulletin will be provided to dealers 1^st Quarter 2021, when it is anticipated that parts ordering information, repair instructions and owner refund instructions will be available to support this safety recall.
• IMPORTANT: Dealers should open a Repair Order (RO) only when a full dealer bulletin is published.  Opening a RO against an Awareness or Advance Notice will result in warranty rejections against a recall.

 

New! PARTS REQUIREMENTS / ORDERING INFORMATION

• Parts will not be available until 1^st Quarter 2021.
• DO NOT condemn the HCU or other components before the applicable diagnostics have been completed.
• When a complete dealer bulletin is provided, ordering Hydraulic Control Units (HCUs) will be restricted, dealer must contact SSSC to place an order.

 

New! OWNER REFUNDS

Ford Motor Company will be offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date of the publication of a full dealer bulletin (expected 1^st Quarter 2021). Dealers should consider the following when attempting to respond to customer inquiries on possible refunds:

• 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 HCU (base part number 2C215) replacement.
• Parts considered normal maintenance will not be covered under this program and cannot be claimed as related damage (e.g., brake pad replacements) as outlined in the vehicle’s owner manual and warranty guide.
• Refunds are not being processed until the complete Dealer Bulletin is available to dealers 1^st Quarter 2021.

 

CUSTOMER NOTIFICATION

Owners of record will be notified of this safety recall via first-class mail in January. A second notification will be mailed after repair instructions and parts ordering information have been provided to dealers.

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 $21,000 per vehicle.  Correct all vehicles in your new vehicle inventory prior to delivery.

 

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 Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab.

 

Sincerely,

 

David J. Johnson

 

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January 2020

 

* * * IMPORTANT SAFETY RECALL * * *

Safety Recall Notice 19S54 / NHTSA Recall 19V-904

2006 Fusion
Your Vehicle Identification Number (VIN):

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has decided that a defect which relates to motor vehicle safety exists in your vehicle, with the VIN shown above.

We apologize for this situation and want to assure you that, with your assistance, we will correct this condition. Our commitment, together with your dealer, is to provide you with the highest level of service and support.

What is the issue?	On your vehicle, a valve in the hydraulic control unit of the anti-lock braking system may be stuck open.
What is the risk?	This may result in extended brake pedal travel required to stop the vehicle, increasing the risk of a crash. The condition does not result in a loss of braking function and the vehicle can be brought to a controlled stop.
What will Ford and your dealer do?	Ford Motor Company is working closely with its suppliers to produce parts for this repair. When parts become available, Ford Motor Company will notify you via mail to schedule a service appointment with your dealer for repairs to be completed free of charge (parts and labor). Parts are anticipated to be available late first quarter 2020.
What should you do?	When parts are available, Ford Motor Company will send a letter to inform you that parts are available and to contact your dealer to schedule a repair. Ford has not issued instructions to stop driving your vehicle under this safety recall. When parts are available, you should contact your dealer for an appointment to have your vehicle remedied as soon as practicable. You can continue to safely drive your vehicle. If you do not already have a servicing dealer, you can access www.Fordowner.com for dealer addresses, maps, and driving instructions. Please note: Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

 

Thank you for your attention to this important matter.

Ford Customer Service Division

 

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Enero de 2020

 

* * * CAMPAÑA DE SEGURIDAD IMPORTANTE * * *

Aviso de campaña de seguridad 19S54 / Campaña 19V-904 de la NHTSA

2006 Fusion
Número de identificación del vehículo (VIN):

Este aviso se le envía de acuerdo con la Ley Nacional de Seguridad y Tránsito de Vehículos de los EE. UU. Ford Motor Company ha determinado que su vehículo presenta un defecto relacionado con la seguridad del motor, con el VIN que aparece más arriba.

Lamentamos esta situación y deseamos asegurarle que, con su ayuda, corregiremos el problema. Nuestro compromiso, junto con el de su distribuidor, es ofrecerle servicio y apoyo de alto nivel.

¿Cuál es el problema?	En su vehículo, una válvula en la unidad de control hidráulico del sistema de frenos antibloqueo podría estar atorada en abierta.
¿Qué riesgo existe?	Esto podría traducirse en un mayor recorrido requerido del pedal del freno para detener el vehículo, lo cual aumenta el riesgo de choque. Esta condición no provoca una pérdida de la función de frenado y el vehículo se puede detener de forma controlada.
¿Qué medidas adoptarán Ford y su distribuidor?	Ford Motor Company colabora estrechamente con sus proveedores para fabricar las piezas para esta reparación. Cuando estas estén disponibles, Ford Motor Company le avisará mediante correo para programar una cita de servicio con su distribuidor y así realizar las reparaciones sin costo alguno (piezas y mano de obra). Se prevé que las piezas estarán disponibles a fines del primer trimestre de 2020.
¿Qué debe hacer?	Cuando las piezas estén disponibles, Ford Motor Company le enviará una carta para informarle la disponibilidad de estas y solicitarle que se comunique con su distribuidor a fin de programar la reparación. Para esta campaña de seguridad, Ford no ha emitido instrucciones de no manejar el vehículo. Cuando las piezas se encuentren disponibles, deberá ponerse en contacto con su distribuidor a fin de programar una cita para solucionar este problema lo más pronto posible. Puede continuar manejando su vehículo con seguridad. Si aún no tiene un distribuidor para realizar el servicio, puede acceder a www.Fordowner.com para conocer las direcciones de los distribuidores, ver mapas y obtener las instrucciones para llegar. Tenga presente que: la ley federal exige que los arrendadores de vehículos que reciban este aviso de campaña envíen una copia del mismo al arrendatario en un plazo de diez días.

 

Gracias por su atención en este asunto sumamente importante.

Ford, División de Servicio al Cliente

 

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October 2020

 

* * * IMPORTANT SAFETY RECALL * * *

Safety Recall Notice 19S54 / NHTSA Recall 19V-904

2006 Fusion
Your Vehicle Identification Number (VIN):

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has decided that a defect which relates to motor vehicle safety exists in your vehicle, with the VIN shown above.

We apologize for this situation and want to assure you that, with your assistance, we will correct this condition. Our commitment, together with your dealer, is to provide you with the highest level of service and support.

What is the issue?	On your vehicle, a chemical reaction between aged DOT 3 brake fluid and the zinc plating inside the Hydraulic Control Unit (HCU) may result in a gel formation, which may cause the HCU valve to be stuck open.
What is the risk?	If the HCU valve is stuck open, this may result in extended brake pedal travel required to stop the vehicle, increasing the risk of a crash. The condition does not result in a loss of braking function and the vehicle can be brought to a controlled stop.
What will Ford and your dealer do?	Ford Motor Company is working closely with its suppliers to produce parts for this repair. When parts become available, Ford Motor Company will notify you via mail to schedule a service appointment with your dealer for repairs to be completed free of charge (parts and labor). Parts are anticipated to be available 1st quarter 2021. When parts are available to repair your vehicles, Ford Motor Company will authorize your dealer to confirm the proper function of your HCU using Ford’s Integrated Diagnostic Software system.  The HCU inspection and following service actions will be performed free of charge (parts and labor). If the HCU passes the inspection, the brake system will be pressure flushed with DOT 4 brake fluid, the DOT 3 reservoir cap will be replaced with a new DOT 4 cap, and you will receive an updated owner’s guide insert. If the HCU does not pass the inspection, the HCU will be replaced and the brake system will be pressure flushed with DOT 4 brake fluid, the DOT 3 reservoir cap will be replaced with a new DOT 4 cap, and you will receive an updated owner’s guide insert.
What should you do?	When parts are available, Ford Motor Company will send a letter to inform you that parts are available and to contact your dealer to schedule a repair. Ford has not issued instructions to stop driving your vehicle under this safety recall. When parts are available, you should contact your dealer for an appointment to have your vehicle remedied as soon as practicable. You can continue to safely drive your vehicle. If you do not already have a servicing dealer, you can access www.Fordowner.com for dealer addresses, maps, and driving instructions. Please note: Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
COVID-19 (CORONAVIRUS)	Ford dealerships have implemented enhanced protocols to ensure both your safety and the safety of dealership employees. This includes specific procedures for cleaning and disinfecting customer vehicles before and after each vehicle is serviced. In most places, vehicle service has been deemed a critical service. Please contact your local dealer to confirm current service hours. For more information on how Ford and your local dealer are working hard to keep you on the road during these challenging times, please visit owner.ford.com.
Have you previously paid for this repair?	You may be eligible for a refund of previously paid repairs. Refunds will only be provided for HCU replacement (base part number 2C215), with a symptom of extended brake pedal travel. Refunds are anticipated to be available 1st quarter 2021.

 

Thank you for your attention to this important matter.

Ford Customer Service Division

 

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Octubre de 2020

 

* * * CAMPAÑA DE SEGURIDAD IMPORTANTE * * *

Aviso de campaña de seguridad 19S54 / Campaña 19V-904 de la NHTSA

2006Número de identificación del vehículo (VIN):  Fusion

Este aviso se le envía de acuerdo con la Ley Nacional de Seguridad y Tránsito de Vehículos de los EE. UU.

Ford Motor Company ha determinado que su vehículo presenta un defecto relacionado con la seguridad del motor, con el VIN que aparece más arriba.

Lamentamos esta situación y deseamos asegurarle que, con su ayuda, corregiremos el problema.

Nuestro compromiso, junto con el de su distribuidor, es ofrecerle servicio y apoyo de alto nivel.

¿Cuál es el problema?	En su vehículo, una reacción química entre el líquido de frenos DOT 3 antiguo y el recubrimiento de cinc en el interior de la unidad de control hidráulico (HCU) podrían provocar una formación de gel, la cual podría generar el atoramiento en apertura de la válvula de HCU.
¿Qué riesgo existe?	Si la válvula de HCU se atora abierta, se podría requerir un mayor recorrido del pedal del freno para detener el vehículo, lo cual aumenta el riesgo de choque. Esta condición no provoca una pérdida de la función de frenado y el vehículo se puede detener de forma controlada.
¿Qué medidas adoptarán Ford y su distribuidor?	Ford Motor Company colabora estrechamente con sus proveedores para fabricar las piezas para esta reparación. Cuando estas estén disponibles, Ford Motor Company le avisará mediante correo para programar una cita de servicio con su distribuidor y así realizar las reparaciones sin costo alguno (piezas y mano de obra). Se prevé que las piezas estarán disponibles el 1er trimestre de 2021. Cuando las piezas para reparar el vehículo se encuentren disponibles, Ford Motor Company autorizará a su distribuidor a confirmar el correcto funcionamiento de la HCU mediante el sistema de Software de diagnóstico integrado de Ford.  La inspección de la HCU y las posteriores acciones de servicio se realizarán sin costo alguno (piezas y mano de obra). Si la HCU aprueba la inspección, el sistema de frenos se lavará a presión con líquido de frenos DOT 4, la tapa del depósito de DOT 3 se reemplazará por una nueva tapa DOT 4 y recibirá un inserto actualizado para el Manual del propietario. Si la HCU no aprueba la inspección, la HCU se reemplazará y el sistema de frenos se lavará a presión con líquido de frenos DOT 4, la tapa del depósito de DOT 3 se reemplazará por una nueva tapa DOT 4 y recibirá un inserto actualizado para el Manual del propietario.
¿Qué debe hacer?	Cuando las piezas estén disponibles, Ford Motor Company le enviará una carta para informarle la disponibilidad de estas y solicitarle que se comunique con su distribuidor a fin de programar la reparación. Para esta campaña de seguridad, Ford no ha emitido instrucciones de no manejar el vehículo. Cuando las piezas se encuentren disponibles, deberá ponerse en contacto con su distribuidor a fin de programar una cita para solucionar este problema lo más pronto posible. Puede continuar manejando su vehículo con seguridad. Si aún no tiene un distribuidor para realizar el servicio, puede acceder a www.Fordowner.com para conocer las direcciones de los distribuidores, ver mapas y obtener las instrucciones para llegar. Tenga presente que: la ley federal exige que los arrendadores de vehículos que reciban este aviso de campaña envíen una copia del mismo al arrendatario en un plazo de diez días.
COVID-19 (CORONAVIRUS)	Los distribuidores Ford han implementado protocolos mejorados con el fin de asegurar tanto su seguridad como la de los empleados de los diferentes distribuidores. Esto incluye procedimientos específicos de limpieza y desinfección antes y después de realizar servicio en cada uno de los vehículos de nuestros clientes. En la mayoría de los lugares, la atención de vehículos se ha considerado un servicio fundamental. Póngase en contacto con su distribuidor local para confirmar las horas de servicio actuales. Para obtener más información sobre cómo Ford y su distribuidor local están trabajando arduamente para mantenerlo en las calles durante estos tiempos difíciles, visite owner.ford.com.
¿Ha pagado anteriormente por esta reparación?	Es posible que cumpla con los requisitos para recibir un reembolso por las reparaciones pagadas previamente. Solo se proporcionarán reembolsos por reemplazos de HCU (número de pieza base 2C215), donde se muestre un recorrido extendido del pedal del freno. Se prevé que los reembolsos estarán disponibles el 1er trimestre de 2021.

 

Gracias por su atención en este asunto sumamente importante.

Ford, División de Servicio al Cliente

 

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Subject:  Ford Motor Company (Ford) Recall No. 19S54 – Certain 2006-2010 Model Year Ford Fusion, Mercury Milan, Lincoln Zephyr and Lincoln MKZ Vehicles Equipped with Anti-Lock Brake Systems – Anti-Lock Brake System Hydraulic Control Unit Valve Function

 

Chronology

December 20, 2016: NHTSA opened PE16-017 on model years 2007-2009 Ford Fusion/Mercury Milan/Lincoln MKZ regarding vehicles experiencing long brake pedal travel or extended stopping distance.

 

January 24, 2017: Ford’s Automotive Safety Department (ASO) opened this issue in their Critical Concern Review Group (CCRG).

 

February 10, 2017: NHTSA and Ford held a joint drive evaluation in Dearborn, MI using Fusion vehicles fitted with an electro-mechanical system that was able to actuate one or two of the normally closed ABS valves to simulate the alleged extended pedal travel condition.

 

March 9, 2017:  Ford submitted its response to NHTSA’s PE16-017.  The analysis identified the potential for an interaction between aged brake fluid and zinc plating on the normally closed ABS valve armatures which formed zinc carboxylate, potentially resulting in stuck open normally closed valves.  Ford did not identify an unreasonable risk to safety due to this condition, and would continue investigating possible causal and contributory factors and would continue to analyze data, ABS assemblies, and fluid samples obtained from the field.

 

August 22, 2017: NHTSA and Ford held a second joint drive evaluation in Dearborn, MI.

 

July 20, 2018: NHTSA opened EA18-002 requesting an update to the ABS module data and analysis and expanding the inquiry to include all 2006-2012 Ford Fusion/Mercury Milan/Lincoln Zephyr and MKZ vehicles.

 

September 28, 2018:  Ford submitted its response to EA18-002.  Ford determined that there had not been any substantial change in the field data or the technical assessment since Ford’s response to PE16-017.  Ford’s engineering analysis showed that while customers driving vehicles with ABS systems that include zinc-plated valves may experience a longer brake pedal travel, the condition does not result in a loss of braking function or loss of vehicle control, and the vehicle can be safely brought to a controlled stop.

 

October 2018 – November 2019: Ford continued to monitor field data and conduct additional engineering analysis.  Ford continued to work with NHTSA to investigate and engaged in ongoing discussion with NHTSA.

 

At a meeting in November with NHTSA, the agency’s perspectives about the nature of the failure were shared with Ford and the agency recommended Ford conduct a safety recall.

 

December 11, 2019: Ford’s Field Review Committee reviewed the concern and approved this field action.

 

Ford is aware of 10 reports of accidents and 2 injuries that may be related to the ABS stuck valve issue.

 

August 13, 2020:  Ford revised the Recall Schedule to indicate that a follow up owner letter will be mailed in November 2020 when parts are anticipated to be available.  Ford also revised the accident report count.

 

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FORD MOTOR COMPANY ISSUES TWO SAFETY RECALLS IN NORTH AMERICA

DEC 20, 2019 | DEARBORN, MICH.

DEARBORN, Mich., Dec. 20, 2019 – Ford Motor Company is issuing two safety recalls in North America. Details are as follows:

 

Safety recall for select 2006-10 Ford Fusion, Mercury Milan and Lincoln MKZ vehicles

Ford is issuing a safety recall for select 2006-10 Ford Fusion, Mercury Milan and Lincoln MKZ vehicles. In some affected vehicles, a normally closed valve inside the hydraulic control unit may stick open, which could result in extended brake pedal travel, potentially increasing the risk of a crash.

Ford is aware of 15 reports of accidents and two injuries that may be related to this condition. This action affects 600,166 vehicles in the U.S. and federal territories. Affected vehicles were built at Hermosillo Assembly Plant from Feb. 22, 2006, to July 15, 2009.

Dealers will inspect the hydraulic control unit for signs of stuck or slow-responding valves and replace the unit, if necessary. The system will be pressure-flushed with DOT 4 brake fluid and the DOT 3 reservoir cap will be replaced with a new DOT 4 cap. The Ford reference number for this recall is 19S54.

 

Safety recall for select 2020 Ford F-150 vehicles for spare tire bead damage

Ford is issuing a safety recall for the spare tire on select 2020 Ford F-150 vehicles. In some affected vehicles, the spare tire bead area may have been damaged when it was mounted onto the wheel assembly. Cuts or tears can potentially damage the bead wire, leading to corrosion over time. Bead-wire corrosion can cause separation of the bead wire, resulting in a rapid loss of air pressure and the tire detaching from the wheel.

Ford is not aware of any reports of accident or injury related to this condition. This action affects 33 vehicles in the U.S. and 51 in Canada. Affected vehicles were built at Dearborn Truck Plant during Nov. 10-21, 2019.

Dealers will replace the spare tire. The Ford reference number for this recall is 19S55.

 

 

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20 Affected Products

Vehicles

MAKE	MODEL	YEAR
FORD	FUSION	2006-2010
LINCOLN	MKZ	2006-2010
LINCOLN	ZEPHYR	2006-2010
MERCURY	MILAN	2006-2010

 

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10 Associated Documents

Interim Owner Notification Letter(Part 577)

RIONL-19V904-7418.pdf 86.091KB

 

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Miscellaneous Document – Notification of Two Recalls

RMISC-19V904-5679.pdf 239.312KB

 

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Manufacturer Notices(to Dealers,etc) – Advance Notice – Safety Recall 19S54 Certain 2006-2010 Model Year Fusion/Milan/MKZ/Zephyr Vehicles Equipped With Anti-Lock Brake Systems; Anti-Lock Brake System Hydraulic Control Unit Valve Function

RCMN-19V904-1720.pdf 113.741KB

 

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Manufacturer Notices(to Dealers,etc) – Dealer Notification re Advance Notice – Safety Recall 19S54 –Supplement #1 Certain 2006-2010 Model Year Fusion/Milan/MKZ/Zephyr Vehicles Equipped with Anti-Lock Brake Systems

RCMN-19V904-5676.pdf 116.319KB

 

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Defect Notice 573 Report

RCLRPT-19V904-2085.PDF 216.003KB

 

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Chronology

RMISC-19V904-0442.pdf 63.197KB

 

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Recall Acknowledgement

RCAK-19V904-3680.pdf 244.912KB

 

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Miscellaneous Document – Chronology re Anti-Lock Brake System Hydraulic Control Unit Valve Function

RMISC-19V904-0518.pdf 101.535KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-19V904-3537.pdf 119.582KB

 

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-19V904-4478.pdf 89.776KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V904&docType=RCL

 

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1 Associated Investigation

Extended Braking Distance
NHTSA ID: EA18002
Dated opened: April 18, 2018

On December 20, 2016, the Office of Defects Investigation (ODI) opened Preliminary Evaluation (PE) 16-017 to investigate reports of braking concerns in model year 2007 through 2009 Ford Fusion and Mercury Milan vehicles. Complainants report that after an ABS braking event (caused by braking on a slippery or uneven surface) the brake pedal moved towards the floor and the distance in which the vehicle stopped increased beyond what was expected by the driver. The cause of the problem appears to be the Antilock Braking System (ABS) Hydraulic Control Unit (HCU), a component manufactured for Ford by Continental Automotive Systems. Hydraulic control valves within the HCU can experience corrosion and become stuck. In some cases, braking returns to normal when the valve(s) subsequently become unstuck. The intermittent condition proves difficult to diagnose and complainants report having several brake system components replaced only to have the condition return.

ODI has identified 544 reports submitted to the agency that relate to this issue in model year 2006-2012 Ford Fusion/MKZ and MY 2006-2011 Mercury Milan, the subject vehicles. Complainants report an increase in pedal travel which in some cases resulted in going past expected stopping points or having to steer to avoid contacting another vehicle; twenty six report a crash with 3 injuries alleged. The Ford reports shown above, which are from PE16-017 and involved the scope discussed above, were similar in content and identified 7 crashes without injury.

During PE16-017, ODI was able to recover HCUs from some complaint vehicles, including some from the reported crashes. The recovered HCUs were sent to NHTSA’s Vehicle Research and Test Center (VRTC) in East Liberty, Ohio for evaluation. VRTC was able to confirm stuck valves and corrosion of the zinc coated control valves, and it’s testing indicates that HCU failures cause increases in pedal travel that may affect braking distance. According to Ford, newer version HCUs have a different coating on the affected valves that do not currently appear to be experiencing corrosion.

In it’s response to ODI’s information request letter, Ford described analysis of two failed HCUs removed from complainant vehicles. In both cases, a gelatinous material found inside the HCU prevented control valves from properly returning to the closed position after actuation. Ford found that an interaction between the valve coating and brake fluid was the likely source of the gelatinous material. It acknowledged that stuck valves can result in increased pedal travel but maintains the affected brake circuit will develop pressure and respond if the brake pedal is pressed sufficiently. While it has not identified an unreasonable risk to safety due to this issue, Ford states that it continues to investigate the possible causal and contributory factors including additional engineering evaluations and testing.

An Engineering Analysis has been opened to assess the scope, frequency, and safety-related consequence of the alleged defect. Based on information received during PE16-017, the scope of the investigation has been increased to include another model, the Lincoln MKZ, and to expand the model years of the subject vehicles.

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