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Ford Fusion repairs by problem area

Engine (24%)

Transmission and Drivetrain (11%)

Brakes and Traction Control (8%)

Suspension and Steering (6%)

Electrical and Air Conditioning (27%)

Paint, Rust, Leaks, Rattles, and Trim (15%)

Other (8%)

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Chart based on 1493 repairs.

Ford Fusion brake repair cost distribution

$2500+ (4%)

$1000 - $2499 (12%)

$500 - $999 (22%)

$100 - $499 (41%)

< $100 (22%)

Chart based on 51 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2014 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed shiftable automatic FWD

15000 mi Warped rotors causing pulsating while braking 

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2013 Ford Fusion 4dr Sedan

turbocharged 240hp 2.0L I4 6-speed shiftable automatic FWD

16000 mi Clicking again this time resolved by chauffeuring the pads and re greasing slider pins. 
27000 mi Calipers sticking and replaced 

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2013 Ford Fusion 4dr Sedan

turbocharged 178hp 1.6L I4 6-speed shiftable automatic FWD

28300 mi pulsing from brakes-dealer resurfaced all 4 rotors under warranty 

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2013 Ford Fusion 4dr Sedan

turbocharged 178hp 1.6L I4 6-speed manual FWD

33000 mi Replaced brake rotors and pads. 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Plug-in Hybrid CVT FWD

15000 mi Car self-diagnostic indicated brake system issue, very likely related to an unknown issue before I took ownership that had already been resolved. 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

36000 mi Brake ABS system...subframe chaffed harness 
36000 mi Parking brake light comes on randomly while driving. 
39000 mi Parking brake light comes on randomly while driving. Shop could not duplicate 

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2012 Ford Fusion 4dr Sedan

240-horsepower 3.0L V6 6-speed shiftable automatic FWD

32200 mi

C $600
Severe brake fade. Total brake loss. Dealer could not duplicate. I took the car home and found my rear calipers siezed and the pads failed. I replaced all pads/rotors/calipers myself and the problem was resolved. 

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2012 Ford Fusion 4dr Sedan

240-horsepower 3.0L V6 6-speed shiftable automatic AWD

103000 mi

US $1670
front and rear breaks/pads replaced 
62000 mi

C $120
vibration when appling brakes. 

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2012 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

27000 mi

US $96
Rear brake pads and rotors were worn out. Uneven wear on driver side pads. Replaced pads, rotors, boots and springs. Completed the repairs myself. 
4000 mi Turned rear rotors. The rear rotors had the equivalent of 20k miles of wear at delivery! Ford would not replace them despite my insistence. I urge new car buyers to look over items like brake rotors and REFUSE delivery if something is wrong. 

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2011 Ford Fusion 4dr Sedan

263-horsepower 3.5L V6 6-speed shiftable automatic FWD

589 mi They replaced one wheel sensor and ABS module. 
21700 mi rotors needed turned 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

21880 mi

C $100
rear left brake worn out, had to change disk too. 
57000 mi

US $75
Rear brake caliper was sticking. 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

25000 mi Electronic stability control (Advancetrac) warning light and warning message was intermittently coming on and turning off at low and high speeds, dealer was unable to replicate problem. Problem has not occurred in the month afterwards. 
2000 mi Car computer display reported AdvanceTrac needed service. Dealer diagnosed control module needed to be replaced but did not have it in stock. Dealer ordered it for next day repair. AdvanceTrac module was successfully replaced. New car so covered under warranty. 
36880 mi

C $600
Rear break pads and discs replaced. 
39000 mi

US $233
rear pads and rotors ruined at only 39,000 miles. fronts ok. 
44000 mi

US $300
New brake pads and rotors resurfaced 

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2011 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

6000 mi Loud squeal from right rear disc brake. Dealer checked and found no apparent problem. Clean/adjusted and replaced both rear pads. Made comment that retaining clips appeared to have been redesigned on new pads. 

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2010 Ford Fusion

Engine not specified

93000 mi

US $2300
Out of Town: Brakes spongy suddenly with no warning. Dash lit up like Christmas tree. Brakes pushed to the floor and slowed to a gradual stop. In residential area, 20 mph. Can't imagine if on the hwy. Intermittent issue. Solenoid and brake replaced. in a residential area (THANK GOD) the brakes gave out AGAIN, Identical issues, Identical light show on my dash. Apparently as the solenoid and brake booster went out, they were wearing out the ABS module. Now the ABS module went kaput. 

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2010 Ford Fusion 4dr Sedan

263-horsepower 3.5L V6 6-speed shiftable automatic FWD

67700 mi

US $175
Rear brake pads and rotors were completely shot and needed to be replaced. Replaced pads and rotors 
29000 mi Battery would not hold charge (replaced) and stablilty control module also replaced (worked fine until battery died - don't know which caused which) 
27700 mi Owner observed unusual situation with brakes where when brakes applied, coming to stop moving forward then put in reverse, moving then applying brake a noise occurred. I described it to the dealer as a loose caliper- they may have tightened 

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2010 Ford Fusion 4dr Sedan

240-horsepower 3.0L V6 6-speed shiftable automatic FWD

15700 mi Replaced leaking master cylinder cap. 

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2010 Ford Fusion 4dr Sedan

240-horsepower 3.0L V6 6-speed shiftable automatic AWD

32000 mi

US $290
Parking brake lever was stuck in the engaged position. It was determined that the release button/cable was at fault. The entire mechanism is one unit so the whole thing had to be replaced. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

70520 mi

C $300
replace rotors and pads 
32000 mi

US $180
Car was in for routine maintenance. Mechanic noticed right rear brake pad was almost completely worn out. The suspected cause was the caliper was not sliding freely. the slides were lubricated on reassembly. Unusual problem for only 32K. 
42160 mi

C $300
Rear brakes replaced. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

55360 mi

C $400
Replaced back brakes. 
77000 mi

US $320
Brake pads replaced. 
68000 mi Pads, rotors, calipers 
84000 mi

US $130
warning light on brake air pressure 
19680 mi back passenger caliper became stuck and needed replacement along with pads and rotor. 
5500 mi I had the service light go off for the traction control. It did not stay on for long, but I took it in for them to look at. They saw the alert on their computer but did not see a problem. 
125000 mi replaced the front pads 
89000 mi

US $320
left rear pads wore out in one year, replaced defective caliper and installed new rotors 
104160 mi

C $600
routine brake repairs and adjustments, oil change and tie rotation 
98860 mi

C $300
Front brakes rotors and seized calipers. 
105400 mi

C $500
Replaced front and back pads and rotors. Freed stuck calibers. 
8680 mi The pistons in caliper of rear wheels don't retreat back to their original position after brake being applied. This resulted in wheels being seized if car park in hot(30 minutes) and wet(over night,rusted together) weather. 
30380 mi

C $300
braking pad/rotor worn out prematurely. 
14000 mi

US $150
During inspection, mechanic found the rear brake pads were completely worn away (at 13700 miles). Front pads were fine. Pads were replaced and calipers checked - assumption is calipers locked up or pads rusted so that they would not move. 
30000 mi

US $156
Noted a smell of burning brakes while driving. Rear-left caliper was locked. Took to mechanic, found both rear pads shot-replaced both. Nothing wrong could be found with the calipers; suspect the parking brake froze during cold weather. 
40000 mi

US $390
a bit over 40,000 miles; replaced front pads and rotors and rear rotors. 
56000 mi

US $600
replace all 4 rotors and pads 
88700 mi Replaced rear brakes at 55000 miles. Just want to alert that the rear goes first because of the small size of these brake pads. Front pads are 70+ good. FMC should change this to full size rear pads. 
66340 mi

C $425
Rear brakes were grinding. Dealer replaced rear brake rotors and pads. 

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2010 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

4340 mi brakes squeeling constantly, machined rotors and replaced brake pads, problem fixed 
7000 mi Hybrid Regenerating Brakes software flash 
9800 mi Sync system health-reported brake malfunction (unspecified). ABS code. Dealer had to reflash computer, no malfunction (stored code went active-unknown reason) 

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2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

97000 mi

US $936
Brake fluid was leaking from the master cylinder and there was a leak in the power steering pressurize line. Replaced the master cylinder & power steering line. 
132680 mi

C $250
Replace brake pads 
31000 mi rotors & brakes on 4 wheels to be replaced 
28000 mi

US $270
Brake caliper froze and needed to be sandblasted, greased, and new pads installed. $270 for a rear brake job on car with under 28,000 miles. 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

17000 mi front brakes made a click or pop noise once when cold when backing out of the garage, Clips were installed to eliminate the noise. 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

11000 mi Car makes metallic clunk noise occasionally when switching from D to R or R to D and then applying brakes. Issue was fixed at dealer but then came back. Still not fixed. 
60500 mi

US $500
Caliper froze. Caused pads and rotor damage, had to replace all. 

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2008 Ford Fusion

Engine not specified

102000 mi Brakes gradually stopped working, Fluid was leaking, And needed to be replaced 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

13000 mi Brake caliper :snapping on the disk when brake is applied . 
34000 mi

US $100
Replaced Front Brake Pads and had the Rotors turned. Replaced Pads with Ceramic type from Autozone. Brakes now work great. Did it myself. 
53000 mi

US $120
New rear brake pads and rotors 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

74000 mi Brake pads and rotors 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

81000 mi

US $10
Daughter reported soft brake pedal. After application of ABS (hard braking) pedal would be very soft and brake performance was poor. Did complete brake fluid flush by manual bleeding which solved problem. Amazing improvement. 
64480 mi

C $1200
Full brake system replacement. Pads and rotors. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

165000 mi

US $450
fron brake pads and rotors 
85000 mi

US $150
Replace Rear rotors and pads 
85000 mi

US $600
rear pads and rotors needed replacement 
54000 mi

US $604
All new brake pads & rotors, balky (sticking) LR caliper freed up. Even 3,000 miles later, car stops like brand new. Gas mileage went up 2 mpg city with LR caliper fixed. 
61500 mi

US $1989
In mid-Nov.'14 my brake pedal nearly went to the floor as the ABS kicked in. It didn't recover until the next day, then it was fine for 6 weeks. On 1-3-15 it happened again & stayed that way. Dealer replaced master cylinder & HCU. 
70000 mi

US $461
Left-rear brake caliper had seized, causing those pads to drag & make the whole assembly hot. A garage had freed it up in Spring 2014 but it obviously only lasted a year-and-a-half. A local Ford dealer replaced the caliper this time. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

90000 mi

US $900
replace rotors and brakes 
38000 mi

US $140
Rear brake pads and rotors replaced. One pad had no lining material left. The rest were quite worn. 
100000 mi

US $75
Replaced caliper carriers, front, both. Caliper pins frozen and no longer allowed calipers to move back and forth. 
282000 mi

US $381
Driver's side rear brake caliper replaced. Brake pads replaced same visit. 
91000 mi Brake rotors had to be replaced. Warped 
112300 mi

US $700
corrosion on front rotors prevented proper operation, replaced with rebuilt items 
122000 mi

US $800
Full brake rebuild - new pads, rotors and replaced all four calipers with rebuilt units because the OE calipers were "sticky" from accumulated corrosion. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

94000 mi

US $200
Grinding noise coming from Rear of the car. Replaced rear rotors and pads, and found that the front was also grinding. Replaced front rotors and pads also. 
68300 mi

US $250
Left rear caliper sticking. Replaced along with wear items (pads and rotors). 
84320 mi

C $775
Replace brake pads and rotors 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

111000 mi

US $350
Frozen parking brake cable. Needed replacement. 
107000 mi

US $175
Replaced pads and rotors. Routine wear. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

31620 mi Rear brakes were worn out completely. Lease was up in 2 months so dealer got me out of lease early and got new car. 
102000 mi

US $10
Replaced Slide Pin Bushings on Rear Caliper slide pins due to swelling causing excessive brake drag. 
47120 mi

C $600
Rear drums were replaced because of noise from rear during driving. 
61380 mi

C $300
Front pads and rotors replacement 
103000 mi Noticed sound while braking. Replaced brake pads for two rear axles. 
78000 mi

US $50
Replaced front brake pads 
194300 mi

US $920
Front and rear brakes needed replacing after 80K or so miles 
38000 mi

US $436
Rear rotors and pads. 
41000 mi

US $500
Front wheels pulsating when hard stopping. Front pads and rotors replaced. 

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2007 Ford Fusion 4-door

4-cylinder automatic 2WD

73300 mi

US $350
Needed new brakes, also did an alignment. 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

17000 mi Front rotors needed turning, front calipers needed adjusting. 
30000 mi Front brake rotors needed turning again. 
112000 mi

US $270
replaced worn out front brake pads and rotors 
75500 mi

US $500
Rear brakes and rotors were replaced. 
84000 mi

US $387
Needed pads and rotors 
16120 mi

C $45
"low brake fluid" warning message. Dealer said no code present. Took it in when light finally went on near dealer store. Dealer said master cylinder sensor bad. (ya think?) On repair invoice described part as brake switch. Paid labour only. 
42000 mi

US $1
I had to have the brakes replaced. Not under the extended warranty. 
60000 mi

US $600
The front brakes needed to be replaced. Took the car in and they replaced them. 
98000 mi

US $135
replaced rear pads and rotors 
134000 mi Rear pads worn out on one side only (again). New rotors + the two pads fron the last time. 
6200 mi squeaking brakes 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

79000 mi

US $300
Rear brake pads worn, replaced pads and rotors. Went with Ford OEM pads from parts dept at dealer where I work. 
69440 mi front: brake pads and rotors, rear: just pads 
131000 mi

US $600
replaced pads and rotors for all 4 wheels 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

53940 mi

C $200
Brake pedal went down all the way and brakes were very weak. The service shop said that they bleeded the ABS system and if it happens again will have to replace it. 
55480 mi

C $100
Brake pedal went down all the way and brakes were very weak. Replaced master cylinder and ABS module covered under extended warranty. 
116000 mi

US $500
Replace brake pads and turn/resurface rotors 
127000 mi

US $150
Resurfaced rotors were inadequately turned, and rotors were completely replaced for this trip. Shop put in replacement new brake pads under warranty (no cost). 
130000 mi

US $195
warped brake rotor, turned all 4 
90000 mi

US $125
Original front brakes lasted 86,000. Unreal, this still remains a great car. 
94000 mi Rear brakes. 
97000 mi

US $400
Valve assembly. 
37000 mi Rear brake rotors badly "warped" replaced at N/C by dealer-customer paid for brake pads. Both front headlight assemblies replaced as they were becoming "cloudy" (warranty)  

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Ford Fusion Brake Problems

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 Ford Fusion problems occur, check out our car reliability stats.