Ford: Braking Glitch in 2010 Fusion and Milan Hybrids Will Be Remedied

DEARBORN, Michigan — Ford said Thursday it will update the software of the regenerative braking system on some 2010 Ford Fusion Hybrid and Mercury Milan Hybrids that are already in customers' hands. Ford's action comes on the heels of a similar issue with the 2010 Toyota Prius that is expected to prompt a recall.

"We have received reports that some drivers have experienced a different brake feel when the hybrid's unique regenerative brakes switch to conventional hydraulic braking," said Ford in a statement regarding the two hybrid vehicles. "While the vehicles maintain full braking capability, customers may initially perceive the condition as loss of brakes.

"To be clear, the Fusion and Milan Hybrids' brake system maintains full conventional brakes and full ABS function even as the customer sees visual indicators and hears a chime. The software threshold to transition from regenerative brakes to conventional brakes can cause the system to transition to conventional brakes unnecessarily."

The National Highway Traffic Safety Administration did not list a recall for the 2010 Ford Fusion Hybrid or 2010 Mercury Milan Hybrid as of Friday morning. It also has not opened a defects investigation into the two vehicles.

However, one Fusion Hybrid owner filed a formal complaint with the federal watchdog. That owner reported that the "brakes failed" in late October. "Pedal goes to floor & warning dash lights lit," the owner wrote. "Slowed with parking brake. Brakes okay after engine turn off and restart. Dealer found nothing." After the third incident, the customer reports that "the factory showed the dealer how to look for codes in a different manner. Brakes are continuing to work fine since the dealer fixed them. This is not really a complaint, but I see others on the Internet who are having this problem and the dealers appear to be having trouble like mind [sic] did."

Consumer Reports said it "recently experienced a perceived brake failure with our 2010 Ford Fusion Hybrid.

"As one of our senior engineers slowed for a stop sign at the turnoff to our test facility in East Haddam, Connecticut, the brake pedal went unexpectedly further down than normal but the car barely slowed," said Consumer Reports on Thursday. "He zoomed through the turn, with brake-system warning lights illuminated on the dash. The car more or less coasted to a stop, with what our engineer described as minimal brake feel.

"After switching off the engine and then restarting it, everything returned to normal — no warning lights and full braking capability. We then took the car to our local Ford dealership, where the service manager told us that a Technical Service Bulletin covered this problem."

Consumer Reports says "our case may be rare but is not unique. We located five other similar accounts of perceived brake failure."

The automaker says that the "software upgrade will reduce unnecessary occurrences of the vehicle switching from regenerative braking to conventional hydraulic brakes." Ford says "there have been no injuries related to this condition."

Owners of the vehicles will get a notice from Ford in the mail. The vehicle software will be reprogrammed at dealers at no charge.

Inside Line says: If you own the aforementioned Ford Fusion Hybrid or Mercury Milan Hybrid, take it to your dealer ASAP. — Anita Lienert, Correspondent