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Chart based on 41 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
2006 Ford Fusion 4dr Sedan
221-horsepower 3.0L V6 6-speed automatic FWD
97000 mi
Gasket came off of sunroof glass due to rust in the gasket spine. Ford offers no spare part -- the entire glass must be replaced.
109740 mi
C $500
replace moonroof motor to open and close. Checked fuses and contact switch for functioning and both were not the problem.
111440 mi
C $50
Dealer opinion on why the moonroof motor was not working. Need to replace moonroof motor that is hidden between the inside ceiling of the roof and the outside metal roof. Major job that requires the whole inside ceiling to be removed.
119660 mi
C $250
remove complete inside roof to interior to get at the moonroof motor to just close the moonroof from a vent position to complete closure. Did not replace the motor as the cost for this was not acceptable from the dealers.
135160 mi
C $350
remove motor to sun roof and close sunroof permanently.
115400 mi
US $50
drivers door inner handle snapped causing the door not to lock and unable to exit the vehicle with the window closed
44000 mi
US $100
buzzing noise coming from behind the steering column.
53000 mi
rubbing/bumping sound in front, right of car near tire Busted button and mechanism on front dash compartment. Too costly to fix. Will live with it. Am not happy with the quality of the Fusion plastic interior (dash, door, etc). I expect better...especially for the price paid.
55000 mi
The inside driver's door handle broke. I cannot open the door from the inside; I roll down the window and open it from the outside. I decided not to repair the door handle because of the cost.
127000 mi
US $750
Rust hole is rocker panel
117000 mi
US $20
front door handle broken. Got a part and fixed less than one hour
80000 mi
US $350
Had to replace the driver door handle as it broke and would not lock leaving the doors unable to lock. Door handle stays in the open. American car companies look and feel cheap no matter what American car you buy including trucks and suvs. Had to replace all chrome/plastic inside car as all door handles and fake chrome plastic pieces started to peel off. POS like all American vehicles. Air bag top end cover on dash of passenger side has come loose. Looks really cheap, broken and not attractive to look at. Cheap plastic and parts. Plastic is great for cars but American auto's use cheap built plastic compared to other makers
12400 mi
Replaced lumber support,
34000 mi
Lumbar support fixed
9000 mi
Noise from driver side door.
18000 mi
The plastic trim on the moon roof that hides the gears disconnected from the window and interfered with operation of the moon roof.
24000 mi
US $50
The sunroof guards that hide the metal gears and parts had broken. The repair was fast and covered completely under warranty.
46000 mi
US $40
Driver's inside door handle broke. Replaced the door handle mechanism.
16120 mi
Vacuum lines under front dash in engine compartment would rattle when parked out in cold. Lines insulated and fastened securely as per TSB by Ford.
5000 mi
TSB for rattle on fire wall between 30 and 40 MPH. Rattle still present.
8000 mi
bumper adhesive let go on top of rear bumper 2 days after i bought the car
25000 mi
In for rattle in the rear of the car and previous TSB not done correctly (rattle on firewall). Rattle fixed, TSB redone.
34000 mi
Floor mat worn, dealer wouldnt replace it. Called Ford customer care, Ford required dealer to replace it. Still pending parts. Driver's seat torn, ordered new seat cover. Replaced torn seat cover. IMPROPERY INSTALLED. Had upholstry shop fix. Need to replace trim broken in the process. Do not plan to have dealer do next repair. Floor mats still not in.
44000 mi
seat torn fixed
15000 mi
Had TSB 07-05-10 for wind noise at the B pillar performed.
15000 mi
Started to notice wind noise inside vehicle. I then did research and found the TSB for the B pillar wind noise. Noticed the wind noise was around this area. Took the vehicle to the dealership and they agreed. Part was ordered and arrived in about 2 we
12000 mi
Air leak in drivers window; door rattle; dash rattle
24000 mi
Passenger seat squeaks loudly when occupied. Dealership has not been able to resolve after 4 trips.
26000 mi
This was a continuation of the seat squeak problem noted previously. This time, a new seat track was installed but the squeak remains and now I have a new rattle when no one is in the seat. Before, it only squeaked with someone in the seat.
42000 mi
US $100
Seat squeak on passenger side.
25000 mi
A "buzzing" noise was heard from the firewall area of the car that usually occurred within 15-20 min. after starting. The noise was most prominent at idle and low speeds but generally abated at speeds>40 mph.
The damn door handle broke!!! 2nd time it's happened since I bought car new. First was under warranty period. Cheap ass plastic. The car will not lock when this happens & you have to roll window down to open the door. Irritating FORD!!!
32000 mi
Squeaky passenger seat when 200+ pound occupant aboard.
33000 mi
Seat squeek returned, will go back in the shop in May.
35000 mi
Plastic trim was rubbing on metal frame, was repaired by padding metal frame.
Bought car with center vent broken / recessed into dashboard. Removed bezel around radio and upper cubby to access vent, reseat it into its facemount, and reassemble. No parts were broken or needed replacing, just realigned. 5 min job.
33000 mi
US $20
Upper dash pad delaminating from the underlying structure around the defroster vent, cracking the vent trim. Bought new trim piece at salvage yard and glued pad down with Loctite 410. Good as new.
36000 mi
US $18
Front passenger side door handle broke off - new assembly installed, good as new.
21000 mi
Driver's interior door handle didn't work. Handle link broke, possibly from pulling too hard, but still covered under Manufacturer's Bumper-to-Bumper warranty.
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 2006 Ford Fusion problems occur, check out our car reliability stats.