1 of 6 verified cards · See all · Pick yours
Fusion Hybrid (2013-2020)
High-voltage disable steps, no-cut zones, wait times, and firefighting quick-reference for safely dismantling the 2013-2020 Ford Fusion Hybrid (HEV), sourced from the OEM Emergency Response Guide.
Wait
minutes
after 12V cut before HV contact
Do not touch HV components until wait time has passed
FRONT
MID
REAR
HV pack
- SD — HV manual service disconnect — behind the DRIVER-SIDE rear seatback (orange handle ~100mm). Fold rear seat back down, remove cover; pull LPA tab forward, pull lever out, rotate to horizontal, remove. No special tool. No cutting.
- 12V — 12V lead-acid battery — trunk/cargo area, driver side. Disconnect negative cable as a disable step.
Schematic zones only — front/mid/rear are approximate. Verify exact locations against the OEM Emergency Response Guide.
First 10 minutes — pre-flight
Before you touch the vehicle. Run this once for every inbound EV or hybrid.
Park downwind, on level ground
If the pack is in thermal runaway it will vent flammable + toxic gas. Stay upwind. Block wheels.
PPE on: HV-rated gloves, safety glasses, no jewelry
Class 0 (1000V) rubber insulating gloves with leather over-protectors are the floor for any HV work.
Walk-around: damage scan + signs of pack compromise
Coolant pooling, white smoke/vapor, hissing, bulging panels, exposed orange cables, or chemical smell = stop. Treat as live and call OEM hotline.
Confirm the vehicle is this card (year, make, model)
Pack location and disable procedure differ between generations. Use the distinguishing visual to be sure.
Locate your fire suppression and first-aid kit before starting
Water is the only effective agent on Li-ion. Dry chemical, foam, and CO₂ will not stop a runaway. Have ≥250 gallons accessible.
HV Disable
Primary
Remove the manual high-voltage service disconnect (NO cutting, NO special tool). Ford procedure (Fusion Hybrid): 1. Secure the vehicle: shift to PARK, ignition OFF; on push-button cars confirm the READY light is OFF; block the wheels. 2. Disconnect the negative cable from the 12V battery. 3. Access the HV service disconnect behind the driver-side rear seatback: fold the rear seat back down and remove the cover. 4. Pull the Lever Position Assurance (LPA) tab toward the front of the vehicle to release it. 5. Pull the lever handle outward to disengage the interlock. 6. Rotate the lever to horizontal. 7. Remove the high-voltage service disconnect. 8. WAIT 5 MINUTES for residual voltage to dissipate, then meter-verify zero volts on the orange cables before contact. No special tool is needed — the disconnect is a hand-pulled lever (Ford p11 lists only the LPA-tab/lever-pull steps).Behind the rear seatback on the DRIVER'S side (Ford OEM-text). Fold the rear seat back down and remove the cover to access. The disconnect is an orange rectangle with a molded plastic handle ~100 mm (4 in) long. (On the Fusion ENERGI it is on the PASSENGER side — confirm you are working a Hybrid, not an Energi.)
Backup
Disconnect the negative cable from the 12V battery (Ford lists this as a disable step in its own right). Also: ignition OFF disables HV; a high-voltage fuse and the HV interlock circuit auto-disable HV; thermal sensors disable the pack above 60C/140F.12V battery is in the trunk / cargo area on the DRIVER side (Ford OEM-text: "Located in the trunk area of the vehicle"; removal steps: "the 12V battery located in the cargo area on the driver side").
Note
DISABLE IS A PULL, NOT A CUT. Ford's documented method for the Fusion Hybrid is
removal of the manual high-voltage service disconnect behind the DRIVER-side rear
seatback — no cutting, no special tool. Do NOT cut the orange HV cables and do NOT
penetrate the battery or its case (explicit Ford "Do Not Cut" guidance).
WAIT TIME (Ford OEM-text, Battery Removal Guide page 21): "Wait 5 minutes after the
service disconnect plug is removed before continuing service. This allows any
residual voltage in the high voltage system to dissipate." Treat as a minimum;
meter-verify zero volts before contact.
Ford OEM-text, two warnings you cannot ignore:
1. "Removing the high-voltage service disconnect will disconnect the high-voltage
from the vehicle. The battery pack will remain live and dangerous."
2. "Depowering the high-voltage system does not dissipate the high-voltage inside
the battery." Never open, breach, or pierce the pack case.
ALWAYS ASSUME THE VEHICLE'S HIGH-VOLTAGE SYSTEM IS POWERED UP (Ford). On a
submerged car, do NOT extract until the HV battery has discharged (Ford: indicated
by the absence of bubbling or fizzing) — and still treat it as live.
12V battery & SRS
12V location: Trunk / cargo area on the DRIVER side (Ford OEM-text: "Located in the trunk area of the vehicle"; removal steps reference "the 12V battery located in the cargo area on the driver side"). Typical automotive 6-cell lead-acid design.
Ford disable step: "Disconnect the negative cable from the 12-volt battery." Turning the ignition OFF also disables HV (any time the 12V system is off, HV is disabled). The Battery Removal Guide sequence is: depower HV via the service disconnect (page 11), then disconnect and isolate the negative battery cable.
Pack & no-cut zones
Pack location: Lies FLAT in the trunk / luggage area, just behind the rear seat back, under the cargo cover (Ford OEM-text: "Lies flat in the trunk area, located behind the rear seat" / "located in the forward portion of the luggage compartment ... just behind the rear seat back under the luggage compartment cargo cover"). Rear-mounted pack, NOT a floor/underbody pack.
Pack chemistry: Lithium-ion (sealed). Ford (OEM-text): "Sealed lithium battery"; the cells contain "a base electrolyte, consisting of lithium hexafluorophosphate and organic solvents." The Salvage Yards note calls it a "Lithium-Ion high-voltage battery pack (Li-Ion HVB)." NOTE: this is the 2nd-gen Fusion (2013-2020) Li-ion pack; the 1st-gen Fusion Hybrid (2010-2012) used a NiMH pack — do not apply this card to a 2010-2012 car.
cable color:Orange
Do not cut:
- Orange high-voltage cables (entire routing) — Ford: "Do not cut any of the high-voltage under vehicle or under hood cabling (all high-voltage cabling is orange in color)."
- HV cabling run along the UNDER-LEFT side of the vehicle — Ford: HV cabling "runs from the high-voltage batteries under the left hand side of the vehicle to the underhood compartment."
- The high-voltage battery / pack case — Ford: "Do not cut the high-voltage battery case. Do not penetrate the batteries or case in any way."
- Trunk / luggage area where the HV battery lies flat behind the rear seat back (Ford-stated pack location)
- HV floorpan wiring from the pack to the transaxle / DC-DC converter / electric A/C and heater (Ford-stated routing)
- SRS components (steering column, A/B-pillars, roof rails, seat-mounted side airbags) — general SRS no-cut convention, not enumerated in this Ford document
- Seat-belt pretensioners — general SRS convention, not enumerated in this Ford document
Reinforcement (UHSS):
- A-pillars
- B-pillars
- Rocker panels
- Rear bulkhead / package-tray structure around the trunk-mounted HV pack
Pack piercing risk: The sealed Li-ion pack lies flat in the trunk behind the rear seat back, bolted to the floor pan with five fasteners (Ford). Any tool that penetrates the trunk floor, rear bulkhead, or rear seat-back region (recip saw, cutoff wheel, spreader tip, fork-truck tine, jack stand) can breach a cell. Ford: "Do not cut the high-voltage battery case. Do not penetrate the batteries or case in any way." If the battery is crushed, electrolyte can leak; if exposed to intense heat it can release flammable and toxic gases. The pack stays internally live even after the service disconnect is removed — never open or pierce the case. Be alert for DELAYED fire with damaged Li-ion batteries (Ford).
Isolate damaged vehicle 50 ft from exposures.
Open NHTSA recalls (2)
Live from NHTSA. Cross-check the VIN against nhtsa.gov/recalls before work.
Responder-relevant (2)
18V592000 · MY 2013 · EQUIPMENT:ELECTRICAL
Ford Motor Company (Ford) is recalling certain 120V Convenience charge cords that were supplied with and sold for use with 2013-2015 Ford C-Max Energi and Fusion Energi vehicles and 2012-2015 Ford Focus Electric vehicles. Cords with part numbers FM58-10B706-AA, FM58-10B706-AB, FM58-10B706-AC, FM58-10B706-AD, FM58-10B706-AE and FM58-10B706-AF were manufactured without thermistors, and during vehicle charging, increased resistance in the house's outlet or wiring can cause the cord to overheat and melt.
Remedy: Ford will notify owners, and dealers will replace the current cord with a new 120V convenience cord with a thermistor, free of charge. The recall began January 18, 2019. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 18S24.
Filed
14V736000 · MY 2015 · POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)
Ford Motor Company (Ford) is recalling certain model year 2014-2015 Ford Fusion vehicles manufactured July 27, 2013, to October 31, 2014, 2015 Ford Fusion Hybrid vehicles manufactured February 24, 2014, to October 31, 2014, and 2015 Ford Fusion Energi vehicles manufactured July 14, 2014, to October 31, 2014. In the affected vehicles, the key may be able to be removed even while the transmission is not in Park. Thus, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 114, "Theft Protection and Rollaway Prevention."
Remedy: Ford will notify owners, and dealers will repair the vehicles, free of charge. The recall began on December 15, 2014. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 14C11.
Filed
Lift / jack points
Use Ford-designated pinch-weld / rocker lift points only. The HV pack lies flat in the trunk behind the rear seat, secured to the floor pan by five fasteners (Ford), so keep jacks and forks clear of the rear floor / trunk pan to avoid piercing the pack from below. Specific lift points are not enumerated in the Ford Battery Removal Guide — verify on-vehicle.
Fluid hazards
Coolant: Not stated in the Ford guide (HV pack is fan/air-cooled per the removal steps; no battery coolant named). Engine/inverter coolant is a separate conventional loop — verify on-vehicle.
Electrolyte color: Not specified by color. Ford (OEM-text): cells contain "a base electrolyte, consisting of lithium hexafluorophosphate and organic solvents ... absorbed in special polymeric film. The electrolyte will not leak from the battery under most conditions, however, if the battery is crushed, it is possible for a small amount of electrolyte to leak." Exposure can cause skin/eye irritation/burns — rinse with water 10-15 min.
If burning, toxic vapors:
- Hydrofluoric acid (HF) — Ford OEM-text: "very small amounts of eye/skin/lung irritants such as hydrofluoric acid could be released"
- Carbon monoxide — Ford OEM-text
- Combustible hydrocarbons such as methane — Ford OEM-text
- Flammable electrolyte vapor (lithium hexafluorophosphate / organic solvents) — Ford OEM-text
Firefighting
Show firefighting details — Water — LARGE amounts (Ford OEM-text: "Emergency responders should use LARGE amounts of water if fire is present or suspected"; "a fire-hydrant or dedicated fire hose can supply the needed amount"). For containing flames Ford also lists a Class ABC powder-type extinguisher. Ford notes water can cause some arcing/shorting and can react with electrolyte to make more combustible gas and HF, but the cooling/smothering benefit of large-volume water still outweighs that.Verify
Agent: Water — LARGE amounts (Ford OEM-text: "Emergency responders should use LARGE amounts of water if fire is present or suspected"; "a fire-hydrant or dedicated fire hose can supply the needed amount"). For containing flames Ford also lists a Class ABC powder-type extinguisher. Ford notes water can cause some arcing/shorting and can react with electrolyte to make more combustible gas and HF, but the cooling/smothering benefit of large-volume water still outweighs that.
Reignition risk: 24 hours post-fire1 source· 2×
Thermal imaging: required during monitoring
Source
Ford Fusion Hybrid Emergency Response Guide (PDF) →
Last verified · mirror
Confirm this is your vehicle
Show distinguishing visual
Mid-size sedan; "Hybrid" badges on left and right front doors and a "Hybrid" nameplate on the RIGHT side of the trunk lid with the green-leaf/blue-highway hybrid icon; unique engine appearance cover with raised "HYBRID" lettering. DO NOT CONFUSE with the Fusion Energi (PHEV), whose "Energi" nameplate is on the LEFT of the trunk lid and which has a charge port on the left-front fender.
Was this card useful?