A full hybrid mid-size saloon that won early praise, then a long dispute over real-world mileage, before the Energi plug-in and a 2013 redesign.
A full hybrid mid-size saloon sold in the United States from 2009 to 2020, the Fusion Hybrid paired a petrol engine with an electric motor in its first generation, moved to lithium-ion batteries in 2013, and gained a plug-in Energi variant that year.
The Ford Fusion Hybrid was a gasoline-electric version of the mid-size Fusion sedan, sold in the United States across two generations from 2009 to 2020. The first generation paired a 2.5-litre Atkinson-cycle engine with a nickel-metal hydride battery, and the second moved to lithium-ion packs. A plug-in Fusion Energi joined the range in February 2013, and the family became one of the best-known hybrids in the US market.
What is the Ford Fusion Hybrid?
The Fusion Hybrid is a full hybrid, meaning either its petrol engine or its electric motor can propel the car alone. Ford built it at Hermosillo in Mexico alongside the regular Fusion, and it shared its powertrain with the Mercury Milan Hybrid and the Lincoln MKZ Hybrid.
The model was a deliberate move back into hybrids after Ford had last sold one in the Escape Hybrid. Planners expected only about 25,000 sales a year from the Fusion Hybrid and its near-twin, the Milan, and both came from the same Mexican plant as the rest of the Fusion line.
A full hybrid saloon that led Ford's green push, then fought a long battle over the mileage its badge promised.
When did the Fusion Hybrid go on sale?
Ford first revealed the hybrid at the 2005 North American International Auto Show, saying it would arrive for the 2010 model year. It was made available to the press in December 2008 and went on sale in the US in March 2009, alongside the Mercury Milan Hybrid. A second generation followed for 2013.
The Lincoln MKZ Hybrid followed in September 2010 as a rebadged version with its own styling and the same hybrid powertrain. It carried an estimated 41 mpg-US rating, and it offered modest changes to the SmartGauge display first introduced on the Fusion Hybrid.
How did the first-generation hybrid work?
The first Fusion Hybrid combined a 2.5-litre Atkinson-cycle four-cylinder producing 156 hp with an electric motor fed by a 275-volt Sanyo nickel-metal hydride battery. Regenerative braking recovers energy when slowing, and Ford claims nearly 94 per cent energy recovery in city driving. The car could cruise about two miles on battery power alone at up to 47 mph (76 km/h).
The SmartGauge with EcoGuide put two 4.3-inch screens on either side of the analogue speedometer. Drivers could configure them to show battery and fuel levels, and in tutorial mode the right-hand screen grew leaves and vines as fuel-efficient driving continued. The left-hand display showed when the car was running on electric power alone.
How economical was the first Fusion Hybrid?
The EPA rated the 2010 Fusion Hybrid at 41 mpg-US in the city and 36 mpg-US on the highway, or 39 mpg-US combined. Independent tests were more mixed. Motor Trend recorded 33.5 mpg-US over 500 miles of mixed driving, while Car and Driver saw no more than 34 mpg-US over 300 miles.
Results from owners and reviewers varied widely. A Los Angeles test in December 2008 reported 43.1 mpg in city driving, and a single-tank stunt in April 2009 reached 81.5 mpg-US over 1,445.7 miles. Edmunds' long-term test car averaged 31.3 mpg-US over 11,000 miles, which shows how much driving style and conditions shaped the result.
Why were the fuel economy ratings disputed?
Consumer Reports found the 2013 Fusion Hybrid averaged 39 mpg-US in real-world tests, about 8 mpg below the rating. The EPA said hybrids can fall far short of their sticker figures, and Ford defended its testing while acknowledging the variation. The disputed rating was a triple 47 mpg-US figure shared with the C-Max Hybrid.
In July 2013 Ford issued a voluntary software update that allowed electric-only running at speeds up to 85 mph (137 km/h), up from 62 mph, and shortened warm-up by up to 50 per cent. In August 2013 Ford lowered the C-Max ratings and paid rebates to 32,000 C-Max owners. In June 2014 it found an error in its internal testing data, downgraded six 2013 and 2014 models, and made goodwill payments to around 200,000 customers.
What was the second-generation Fusion Hybrid?
The second generation arrived for model year 2013 with a 2.0-litre Atkinson-cycle four-cylinder producing an estimated 185 hp (138 kW) and 130 ft-lb of torque. It used a lithium-ion battery pack in place of nickel-metal hydride, and it was rated at 42 mpg-US combined, up from 39 mpg-US for the first generation.
The top speed under electric power climbed from 47 mph to 62 mph (76 to 100 km/h), and the unit drove the front wheels through an electronically controlled continuously variable transmission. Driver aids included lane keeping, adaptive cruise control, active park assist and blind-spot monitoring with cross-traffic alert.
What is the Fusion Energi?
The Fusion Energi is the plug-in hybrid version, with a 7.6 kWh lithium-ion battery and an 88 kW (118 hp) electric motor. It has a total output of 195 hp (145 kW), and its electric-only range was 20 miles (32 km) in the 2013 to 2016 models, rising to 22 miles (35 km) from 2017.
US retail sales began in February 2013, and the car qualified for a federal tax credit of up to US$3,750 with extra state incentives. Energi owners in California could use high-occupancy lanes with a solo driver. The 2017 refresh added more efficient electric motors and a new fascia, and it lifted the hybrid-mode rating to 42 mpg-US.
How did the MKZ Hybrid and Mondeo Hybrid differ?
The Lincoln MKZ Hybrid shared the Fusion Hybrid's powertrain and had the same base price as the non-hybrid MKZ. It was rated 4 mpg-US combined below the Fusion Hybrid after the 2014 revisions, and it was the model with the largest fuel economy reduction in that round.
In Europe the Ford Mondeo Hybrid used the same 2.0-litre petrol and electric powertrain with a 1.4 kWh lithium-ion battery. Ford took orders in Germany from August 2014, and UK retail deliveries began in December 2014 at a starting price of 24,995 pounds sterling.
Did the Fusion Hybrid sell well?
It sold strongly at first. Ford reported 15,554 Fusion Hybrids sold in 2009 and 20,816 in 2010, when the model became the third best-selling hybrid in the US. By August 2013 sales of the redesigned car were up 275.2 per cent on the same period of 2012, and the Energi achieved record sales that month.
Sales cooled in later years. Hybrid sales across the US fell in 2014 and 2015, and the Fusion Hybrid dropped 30.3 per cent in 2015. A 70.8 per cent rise in 2017 returned it to the number two spot among US hybrids, and total US sales of the family, including the Energi, reached 356,534 by December 2017.
Fusion Hybrid specifications at a glance
| Specification | First generation | Second generation |
|---|---|---|
| Years | 2009 to 2012 (model years 2010 to 2012) | 2013 to 2020 |
| Engine | 2.5-litre Atkinson four, 156 hp | 2.0-litre Atkinson four, 185 hp (138 kW) |
| Battery | 275-volt Sanyo nickel-metal hydride | Lithium-ion pack |
| Torque | 136 ft-lb | 130 ft-lb (180 N-m) |
| EPA combined | 39 mpg-US (2010) | 42 mpg-US (2013 rating) |
| Electric top speed | 47 mph (76 km/h) | 62 mph (100 km/h) |
| Plant | Hermosillo, Sonora, Mexico | Hermosillo, Sonora, Mexico |
What awards did the Fusion Hybrid win?
The 2010 Fusion Hybrid took the North American Car of the Year title at the Detroit show in January 2010, and the whole 2010 Fusion line-up was named Motor Trend Car of the Year. The entire 2013 line-up, including the hybrid and plug-in models, won the 2013 Green Car of the Year award.
Other honours included Consumer Reports picks that led the Green Car category in 2010 and 2011, and Kelley Blue Book's top 10 green car lists in 2009 and 2010. Car and Driver listed the hybrid among its 10 best cars in 2009.
What tax credits were available?
The first Fusion Hybrid could earn a hybrid tax credit of up to US$3,400 when bought by 31 March 2009. The credit fell to US$1,700 for purchases by 30 September 2009 and to US$850 for purchases from October 2009 to 31 March 2010, then phased out on 1 April 2010.
Energi models bought in or after 2010 were eligible for a US$4,007 tax credit based on battery capacity, and the 2013 car also earned a US$1,500 California state tax rebate.
Did Brazil get the Fusion Hybrid?
Yes. The Brazilian version was unveiled at the 2010 Sao Paulo International Auto Show, with sales starting in November 2010. It was imported from Mexico, and it was the first full hybrid sold in Brazil. Its engine and fuel system were tested with the country's mandatory E20 to E25 ethanol blends.
How much did owners actually drive on electricity?
Ford's telematics data from electrified vehicles, covering more than 610 million miles, showed that Energi drivers averaged 13,500 miles a year, with about half of those miles run in all-electric mode. The average daily commute for Energi owners was 42 miles, and most customers charged their cars only at home.
The EPA's utility factor estimates gave the Fusion and C-Max Energi 45 per cent of miles in electric mode, compared with 83 per cent for the BMW i3 REx, 66 per cent for the Chevrolet Volt and Cadillac ELR, and 29 per cent for the Toyota Prius plug-in.
What tests did the Fusion Hybrid face against the Camry?
Motor Trend ran a Fusion Hybrid against a Toyota Camry Hybrid and found the Ford managed 31.8 mpg-US over 160 miles, while the Camry returned 32.7 mpg-US. The magazine concluded that the EPA figures were reachable only with very careful driving, and that typical driving would fall well short.
How did sales develop in 2011 and 2012?
In 2011 the Fusion Hybrid sold 11,286 units and ranked sixth among US hybrids, while the Lincoln MKZ Hybrid sold 5,739. Fusion hybrid sales rose 24.9 per cent in 2012, and hybrid models made up 5.8 per cent of the 241,263 Fusions sold that year.
What changed with the second-generation display?
The 2012 redesign gave the SmartGauge with EcoGuide a newer look and customisable MyView features. One new feature, Brake Coach, gave instant feedback on braking habits and advice on getting the most from regenerative braking. The left-hand display still showed electric-only running and battery charge.
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