HolyRoller

Just wanted to share an experience I had with my former 2015 Ford Fusion. Everytime I would put gas in my car, I noticed a spark from the nozzle tip to the filler neck. I took it to the dealership but they couldn't explain it. No matter what I did to discharge any static electricity from myself and the nozzle before inserting it into the car, there would be a spark. I started thinking back to when I first started noticing it and realized it was just after I got new tires (went from factory Michelin Energy to a Yokohama tire). I had Discount Tire put new Michelin Energy tires back on the car and the problem went away.

Unfortunately, I just received the letter in the mail today. My car has been at the dealership since Tuesday morning because the CEL came on. Turns out to be coolant intrusion into cylinders 2&3 from a bad head design. Ford is installing a redesigned head in my car as I type this. I guess the original design has a coolant port between the 2&3 cylinders and the new design removes that port. Ironically, the dealership had my car about a month ago to check it for coolant intrusion and they found nothing at the time (car would blow white smoke upon a double downshift). Less than 2K miles later, they are rebuilding half the engine.

And, ironically, I received this in the mail today while my car is at the dealership being repaired for what this bulletin is trying to prevent. #Isn'tItIronicDontYouThink?

I read the SSM, but my service advisor was very clear that a short block replacement IS necessary and drew me a diagram to show the difference between the current head design and the one in the rebuild kit.

Had a similar issue with my '15 Fusion 2.5L. Was the electric power steering rack.

Just wondering if anyone else has heard of this or not. The other night, on my way home from work, the CEL came on. Took it to the dealership the next morning. Later that day, the service advisor calls to say it's a misfire on cylinders 2 & 3 due to a coolant leak. Fusion has just over 16K miles on it. The odd part is that less than a month prior (15K mi), the same dealership did a full check on the engine because I complained of white smoke being blown when the car does a double downshift. They couldn't recreate the issue and said the cylinders are bone dry and there is no indication of any issues with the engine. Now, I'm in a loaner car and won't get my car back until the end of next week because the dealership has to do a top end rebuild on my car. The service advisor told me that Ford just came out with a bulletin recently about the problem. I guess the issue is an extra coolant port that runs between cylinders 2 & 3 is the culprit and the new head design eliminates that port. At least the car is under warranty and I'm only in a 3 year lease.