SVT Lightning

I did not notice a correct/recent answer to this issue. Ford Fusion (or any car in general 2000+/newer) will not start properly after refuel. This issue is caused by the Purge Control Valve (PCV Failure). This part is approximately $30-40 and will resolve the refuel/start-up issue in not only the Ford Fusion, but any car that is dating from 2000 and up. Be aware that some vehicles have 2 replacement sites, however you will want to replace the one located at the rear of the engine after the intake.

bbf, I definitely understand where you are coming from and your points are well-made, and well-taken. That is exactly why I began posting here today, to receive some unbiased, honest, and helpful insight towards the issues that I'm facing. The pad percentage that I estimated only varied because when physically holding it/viewing it, it's virtually in excellent condition between 80-90% life left on the pad. So just in comparison to the destroyed rear-passenger rotor and lack of a pad, I just made the comparison really clear that there is obviously a caliper malfunction involved. Thanks for pointing that out! I understand the lack of "blower motors" in stock as well, but I guess I was just expecting efficient service, as opposed to the service I've been receiving with all of the other issues that I'm facing. It was just one of those "Nice, just my luck, of course they don't have the part that I need." scenarios. I'll search the area for respected dealerships and give another one a try. Thanks guys for all of the helpful advice, I really do appreciate it. I will most definitely keep everyone updated. I'm pretty mechanically inclined, and I'm sure this can all be fixed. It's just the frustration of owning a new vehicle under warranty, and receiving the run-around that is frustrating me beyond belief. If they would even provide me the parts under warranty, I would volunteer to do the labor myself (we all know it doesn't work that way though).

Thanks a lot, bbf! I definitely appreciate the advice. Though I truly hope it does not have to come to legal action, it is definitely a last resort that I would be willing to follow through with.

I did a little bit of Google research as well, and it appears the Ohio limit is 1 year / 18,000 miles for an issue that takes 3 attempts to fix the issue, with no success. Here's the guidelines Ohio Attorney General - Lemon Law Guidelines

I do apologize. I'm from Ohio. I always maintain a personable and friendly attitude with the dealer, and do a pretty good job of hiding my anger and frustration. I would definitely not be threatening in any way, because that only leads to further headache. I just want the car to be fixed to Ford's well-known standards. Ford has been in the blood for generations, and I would love to keep it that way. Thanks for the advice, Grey!

Also, I have documentation regarding my "12 point checks" declaring that all aspects of the vehicle are still in good/excellent condition. My last maintenance was at 22,000 for an oil change and inspection, where the brake pads/calipers/rotors were labeled as "GOOD". I do not see any way that I can be charged for the repair on the rotor when just 5,000 miles ago they claim to have physically verified that it was in Good/Excellent condition. I also saved all service/repair orders, as well as warranty work that was done.

I haven't tried an alternate Ford dealership yet. It is frustrating that they seem to not have a clue as to what they are doing, in terms of the technicians and the manager of the service department, but I keep giving them that 9th and 10th chance to rectify the situation. The vehicle is still under warranty, so I play the "I know nothing about cars, so you fix it because it's under warranty" card. Once it is no longer under warranty, I'll maintain/repair the vehicle myself. I just can't see myself having any better luck 3 years from now with all of these issues that seem to be leading to major repairs down the road. I commute 90 miles round trip to-from work every day, so the 9,000 miles until my factory warranty expires is not that far away. With the transmission apparently dying a slow death, and the engine's clacking getting gradually louder, I can only assume that in the next 2-3 years I'll be looking at $2,500-4,000 in repairs out of my pocket on a 3 year old vehicle fresh-off warranty. Does anyone think that with the above problems that I've stated having, I could apply for the Lemon Law? Does anyone have knowledge or experience with the Lemon Law, or thoughts? I would hate to take this path, but I really would rather not eventually replace my transmission and endure engine repair before 50k.

By no means am I "bashing" on the Ford Fusion. I consider myself one of the unlucky ones to have purchased a "not-so-well-manufactured" vehicle. I have a 2010 Ford Fusion SE, and I've had nothing but issues with my vehicle after hitting 4,000 miles. I currently have approximately 27,400 miles on the car. Prior to 4,000, I loved the Fusion and it was a very reliable and comforting vehicle to commute to work in. I had peace-at-mind that I had made a wise decision buying it, with all of the great write-ups on it from MotorTrend, Top Gear and other unrelated sources. At 4,000 miles I had a repeat issue with the Service Engine light appearing. The first of three visits to the dealership determined that, in the words of the Service Manager, a "simple fuse was blown". On my way home from the dealership, the light appeared again. I returned 2 days later and was told, in lamens terms again by the Service Manager, that "there's an issue with something that traces gasoline evaporation, and we'll have it fixed in 2 hours". Mind you, I can't get an intelligent response as to what is wrong with the vehicle because I'm repeatedly given the above lines. About 1 day later I saw the light appear again. This time I was told that the "gas tank neck needs replaced due to a vapor leak". I had this fixed as well, and was on about my business. The next issue I had was a loud and obnoxious clacking noise from the motor, resembling a bent push-rod on a 2000 Ford SVT Lightning (I know because I've experienced this). I was told that it was normal injector noise coming from "newer" 4 cylinder motors. Next, I had the transmission issues with the erratic/hard shifting. This received the PCM Flash, and all was well for about 2 weeks. To this day, I've returned the car to the dealership because of the problem reoccurring, and I'm repeatedly told that it passes all stress-tests, and nothing is wrong with it. My 4 cyl. should not be revving to 4000 rpm sporadically just to shift into 2nd gear, or 2nd to 3rd. No vehicle should, to be exact, unless you're in a performance vehicle at the drag-strip. My latest problem, which needs to be fixed asap, is that the rear-passenger rotor is being destroyed as I drive. Braking causes a loud grinding noise, that is able to be heard by people standing 500 ft. away. It's clearly obvious that the caliper has either seized, or is dragging, or both, yet I'm told it "may not be covered under warranty because the pad may be bad/faulty". The pads are still OE, as I have 27,000 miles on the car. The driver-side rear pad is still at about 80% life, as 99% of my driving is highway. When the driver side is 90%, and the passenger side is digging 1/4" grooves into my rotor, this is by no means a lack of maintenance on my part. *EDITED THIS IN* Also in combination with this issue, is my heater blower motor issue. I have been waiting 3 weeks for this motor to come into the dealership, as I was told that none were available in the country when I first was told that the blower motor is bad. The heater makes a high-pitched squaking/clicking noise, and increases with fan speed. I am at the point now where I need to blast the stereo just to avoid hearing my rotor being shaved to nothing, and my heater reminding me that it's needing fixed. Needless to say, I loved my Ford Lightning, and I hate my Ford Fusion. Even though I'm at 27,000 miles, I am considering the Lemon Law as a last resort to get this nightmare off my hands. It seems that I'm at the dealership on my days off, more than I'm at home. I am really happy for anyone that has good luck with their Fusion. I loved the car at one time myself.

I have this same exact issue at this time. I currently have 27,400 miles on my 2010 Ford Fusion SE. After taking it in to the dealership, for approximately the 16th time (different issues), I was told that I need a new blower motor. The blower motor would not be available for 3-4 weeks as well, as I was told that "No blower motors for the '10 Fusion SE are available in the country at this time". Overall, this is my second Ford, and my last Ford. I'm currently gathering my maintenance history, as well as documented repairs by the dealership for a potential Lemon Law ruling.