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Chart based on 40 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
Battery died. Would not hold a charge. Replaced under warranty.
62000 mi
US $159
Battery died again. Car eats batteries every 2-3 years. Due to battery already replaced under warranty once it was not covered a second time. Had to purchase a new battery this time.
65000 mi
US $100
AC sensor and damper. Dash had to be removed to accomplish the repair. Vehicle had Ford CPO Premium extended warranty for all was covered except $100
Windshield washer pump not working Heater blower motor making noise Horn honking randomly/ headlights flashing randomly/ car would be found running without using remote start.
9380 mi
Blower motor replaced
22000 mi
Left license plate lamp socket rusted out. bulb burned out.
35000 mi
US $100
Shifter control switch went out causing battery to discharge over night
14000 mi
Flash Sync system to latest version to correct voice recognition and iPod issues.
29000 mi
US $108
Blower motor started making chirping noises. Blower assembly replaced.
7440 mi
Air con fan/motor makes high pitch whistling noise and rattling sound. System whistles when windows closed and inlet is on fresh air. Replaced something. Currently evaluating if it worked or not.
59000 mi
US $100
Dome lamp not turning on when RF door opened. Faulty door latch. Latch replaced under Ford extended warranty. $100 deductible.
18000 mi
Lots of corrosion on terminals, car won't start. Replaced battery under warranty.
124000 mi
Battery began dying during my courier route. Had it replaced the next day.
20000 mi
Retaining ring broken/missing on Power Port. Rear windows did not roll up consistently. Replaced AC blower motor due to noise.
31000 mi
Rear turn signal bulb failed and fused to the socket, requiring the entire socket to be replaced in addition to the bulb.
29000 mi
Fusion would not start/crank 1 day after purchase.
An intermittent problem, dealer replace theft module
Right license plate light housing had rust/stopped working. Found housing cracked.
Replaced housing with Ford part.
29000 mi
Airbag sensor going off at random times. Dealer traced it to a loose wire in the driver's side door panel. Whole airbag system and much of the driver's side SRS wiring was replaced.
Hard starting..slow starting Had to replace battery
82000 mi
US $700
AC compressor was replaced, also had AC control unit replaced with remanufactured unit that turned out to be bad.
116000 mi
US $300
Blower was cutting in and out. Replaced blower motor, resistor pack and wire pig tail.
My understanding is that the blower motor was drawing too much current and in turn damaged the resistor pack and pig tail wires. Wires looked burned.
60000 mi
Air condition blows hot air intermittently. Took it to the dealer when it was acting up but they couldn't fix it because the problem is not consistent and they couldn't diagnose.
60000 mi
US $90
New battery
175000 mi
US $350
Replaced A/C compressor, condenser, & filter/drier and flushed system due to failure.
45840 mi
C $5
Right side marker light replaced. Around 10 minutes. Must disassemble/assemble plastic fender cover which is tricky if there is a cold weather. Light itself is 2 minute job. 8 minutes is to fight with the plastic cover. Dealer wouldn't do it for $20.
91760 mi
C $11
Tail lights replaced - both - one burned in - hard to remove - otherwise it would be less than 10 min.
Battery died with less than 36 months service life. Note car extremely hard to jump start, requires a V6 to get enough juice. It is a big 4, so I'm not surprised.
1000 mi
Airbag deploy light comes on and stays on for most trips. Happened frequently, then infrequently, then seldom. Dealer reset memory code, but could not determine problem. Dealer said drive until stays on, then callback for service appt.
7000 mi
Replacement of driver's airbag clock spring, after airbag deploy dash light came back on again daily for over a week. Dealer pulled 'live' code to determine, part to be replaced.
31000 mi
Noisy heater/AC fan assembly. Dealer damaged bumper, forgot to fix the problem I brought it in for.
43700 mi
The HVAC fan has continually squeaked the past few months. The car is in for a second attempt to repair. The number of days in the shop was due to the holiday season, techs being out and parts having to be ordered. They did give me a loaner.
24000 mi
No cool air present. Mechanic states "impact hole in condenser. Cannot warranty". Taking to another dealer for second opinon
34000 mi
Battery terminal corroded into two pieces. All maintenance done, replaced harness under warranty.
AC was making a chirping noise - Dealership replaced the blower motor under warranty. Battery (small battery - not hybrid battery) would not pass inspection. Replaced battery under warranty.
11000 mi
Airbag deploy dash light stayed on with passenger in seat. Neither dealer or Ford Co. gave satisfactory explanation as to why this happens, Problem reported to NHTSA/ODI. Waiting for answer.
28200 mi
Passenger airbag lite on indicating airbag will not deploy with wife in seat. Dealer says wife does NOT weigh enough (Weight 98 lbs) to activate airbag. Dealer tested according to specs & found no problem. Reported to Federal Govt.
57400 mi
US $357
Failed pedal sensor lit up ABS light. Cost includes tow recommended by dealer, 5 miles.
65000 mi
US $125
Diagnosed failure of reverse sensors on rear bumper. Chose not to repair at dealership. Will DIY when I have assistance.
See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. To see how
frequently 2012 Ford Fusion problems occur, check out our car reliability stats.