As an owner of a 2010 Ford Fusion, if you suddenly find that steering becomes heavy, the steering wheel makes abnormal noises, or the dashboard lights up with a steering fault indicator, it's likely an issue with the Electric Power Steering (EPS) system. This system replaces traditional hydraulic power steering and relies on an electric motor to provide steering assistance. Although the structure is simpler, failures in the coordination between electronic components and mechanical parts are still common. Below, we provide a complete solution tailored to this model, from fault diagnosis to step-by-step repair and precautions.
1. Initial Fault Diagnosis to Avoid Unnecessary Repairs
Before starting any work, use these 3 simple observations to identify the direction of the fault and reduce ineffective operations:
If after starting the vehicle, the steering wheel feels completely heavy like an "old car without power steering," prioritize checking the power supply. The electric power steering system relies on an independent power source. Blown fuses or poor wiring connections are the most common causes, especially since the 2010 model has been in use for years, making wire connectors prone to oxidation.
If you hear a "buzzing" motor sound or a "clunking" mechanical noise when turning the steering wheel, and the power assist occasionally fails, it could be due to worn motor brushes or internal gear jamming in the steering gear, requiring further disassembly for inspection.
If the warning light illuminates (usually an "EPS" symbol or yellow steering wheel icon) and the steering wheel pulls to one side, it's likely an electronic component failure, such as a misaligned steering angle sensor or a control module program error. Use a diagnostic tool to read fault codes (common codes include U0140, C144E).
Recommendation: First, go to an auto parts store or repair shop and spend $5-10 to use an OBD diagnostic tool to read fault codes. For example, if you get code "C144E - Steering Motor Overload," you can directly target the motor issue, avoiding wasting time on unnecessary disassembly.
2. 4-Step Practical Repair: From Simple to Complex
Follow the "easiest first" principle: start with electrical issues that don't require disassembly, then address mechanical and electronic component failures. Beginners can progress step by step:
1 Check Power Supply and Fuses: Low-Cost Solution for Basic Issues
The electric power steering fuse in the 2010 Fusion is located in the engine compartment fuse box. Check the vehicle manual for the exact location (usually marked on the inside of the fuse box cover, corresponding to "EPS FUSE" or "Power Steering").
- Turn off the engine, open the engine compartment fuse box, and use the small clip provided in the fuse box to remove the corresponding fuse. Observe if the metal wire is broken - if it is, it indicates circuit overload. Replace with a fuse of the same specification (usually 20A or 25A; choose OEM or national standard brands to avoid poor-quality fuses blowing again).
- After replacing the fuse, check the wiring connectors near the fuse socket: unplug the connector, gently sand the metal contacts with sandpaper to remove oxidation, then plug it back in tightly to ensure good contact.
- Start the vehicle and test: if steering assist returns, it was just a power supply issue, costing no more than $5; if there's still no assist, proceed to the next step.
2 Test the Power Steering Motor: Determine if Replacement is Needed
The electric power steering motor is the core of the system. In the 2010 Fusion, the motor is located above the steering gear. Removal requires socket wrenches and screwdrivers. When operating, disconnect the battery negative terminal (to avoid short circuits):
- Remove the motor housing (usually fixed with 3-4 screws) and observe the internal brushes. If the brushes are worn to less than 5mm, or if the commutator surface shows obvious scratches or burn marks, the motor has failed and needs replacement (OEM motor about $100-150, aftermarket suitable parts about $50-80; choose products with warranty).
- If the brushes are intact, you can test the motor directly by connecting it to a battery: use wires to connect the motor positive and negative to a 12V power source. If the motor rotates normally without abnormal noise, the motor is fine and the fault lies elsewhere; if the motor doesn't rotate or makes loud noise, replace it directly.
- After replacing the motor, re-secure the wiring connectors and ensure the waterproof sleeves are properly reset to avoid water ingress and short circuits during rainy days.
3 Repair Steering Gear and Sensors: Address Mechanical and Signal Issues
If the motor is normal, the fault is often in the steering gear or sensors:
- Steering Gear Repair: Internal gear wear in the steering gear can cause steering jamming. Disassembling the steering gear of the 2010 model requires professional tools. It's recommended for beginners to replace the entire assembly directly (aftermarket parts about $120-180). If you have repair experience, you can open the steering gear housing, replace the worn gear set, and add special steering gear lubricant (avoid using regular grease as it accelerates wear).
- Sensor Calibration: The steering angle sensor is installed under the steering wheel. If the diagnostic tool shows "sensor misalignment," first try calibration: start the vehicle, turn the steering wheel fully left and hold for 3 seconds, then fully right and hold for 3 seconds, finally return to center. Some models can be reset this way. If calibration doesn't work, replace the sensor (about $40-70). After replacement, use a diagnostic tool to rematch the vehicle data.
4 Reset or Update Control Module: Fix Electronic Program Faults
Some faults originate from control module (ECU) program errors, especially after the vehicle has experienced battery drain or jump-starts:
- Connect a diagnostic tool to the vehicle's OBD port, select "Electric Power Steering System," and perform the "Control Module Reset" function. Clear historical fault codes and restart the vehicle to see if the power assist returns.
- If reset doesn't work, check if there's a software update for the control module of this model (some batches of the 2010 Fusion had power steering issues due to program problems, and dealerships may offer free updates). If an update is needed, go to a Ford authorized dealer or qualified repair shop to complete the update, usually taking 1-2 hours.
3. Post-Repair Precautions to Prevent Recurrence
- Test Steering Performance: After repair, start the vehicle and first turn the steering wheel while stationary to feel if the assist is even and if there are any abnormal noises. Then drive at low speed to check if the steering pulls to one side, and if the steering wheel is stable at high speed (avoid "floating" at high speed due to uncalibrated sensors).
- Regular Maintenance: Check the electric power steering system wiring connectors every 2 years to avoid oxidation. If the vehicle is parked for long periods, start it monthly and let the motor run for 10 minutes to prevent brush corrosion from moisture.
- Be Alert to Abnormal Signals: If the warning light comes on again after repair, do not continue driving, especially on highways. Stop and check promptly to avoid sudden steering failure causing danger.
Summary
Electric power steering system failures in the 2010 Ford Fusion are mostly concentrated in three areas: power supply, motor, and sensors. Most problems can be solved by following the steps: "first read fault codes - check power supply - test motor - repair sensors." Beginners can prioritize low-cost issues like fuses and wiring, while complex motor and control module repairs are best left to professionals. After repair, regular inspections will keep this older vehicle's steering system stable for years to come.