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Ford Fusion repairs by problem area

Engine (25%)

Transmission and Drivetrain (11%)

Brakes and Traction Control (6%)

Suspension and Steering (9%)

Electrical and Air Conditioning (28%)

Paint, Rust, Leaks, Rattles, and Trim (13%)

Other (7%)

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Chart based on 2172 repairs.
See TSBs and recalls for the Ford Fusion.

Ford Fusion electrical repair cost distribution

$2500+ (0%)

$1000 - $2499 (3%)

$500 - $999 (4%)

$100 - $499 (36%)

< $100 (57%)

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Chart based on 368 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2019 Ford Fusion 4dr Sedan

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

31620 mi Could not store stations in radio (AM band only) 

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2018 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

92100 mi

US $400
Radio buttons sometimes do not respond or respond slowly. It is a computer program issue. Alternative is to replace the module. Software repair moderately successful. 

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2017 Ford Fusion 4dr Sedan

turbocharged 325hp 2.7L V6 6-speed shiftable automatic AWD

7000 mi Wiper motor bad 
2480 mi Battery drained and died for 3 straight weekends, and radio stopped working. Sent car to dealer, they reset and fix the radio, did battery test and passed, parked the car for the whole weekend and it started right away Monday morning. 
23560 mi

C $150
Needs new battery. 
1000 mi Remote start feature not working via Ford app or key fob. A part needed to be replaced by the dealer. Car under factory warranty. 
5000 mi 3G modem was replaced for a second time 

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2017 Ford Fusion 4dr Sedan

turbocharged 245hp 2.0L I4 6-speed shiftable automatic FWD

28000 mi Rebooted the navigation because it didn't audibly say turn by turn instructions 
2300 mi Battery was dead several times in the morning. Battery was tested and found to be faulty, was replaced under warranty. Passender front window one touch up would not work at all. Driver's side window one touch up worked but would bound back down. Reprogrammed module (46686) that fixed the passenger side but still had intermittent problems with drivers side bouncing back down. 
5367 mi Received ABS and air bag fault on Ford Pass app saying to take to dealer. Dealer checked and found no issues. Driver's side front window would occasionally bounce back down with one touch up. Reflashed (again) with 46686. Will see how it works. 
8000 mi Battery was still dying if not used for a few days or sometimes sooner. Mentioned ACM (audio control module) TSB to dealer (TSB ID: SSM 46433), they checked it and reprogrammed it. 
14000 mi random re-booting 

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2017 Ford Fusion 4dr Sedan

turbocharged 245hp 2.0L I4 6-speed shiftable automatic AWD

66 mi Dead battery after 3 days. Dealer replaced battery Audio system was not working 
6000 mi Lane keeping was inoperable; Installed new rear-view mirror assembly 
13000 mi Airbag light came on. Dealership had to reprogram the airbags to get the light and error code to clear. 

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2017 Ford Fusion 4dr Sedan

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

Both front windows would not stay up. Up and down. Took back total of 3 times to get software updates. First time only lasted about 2 weeks finally fixed. 

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2017 Ford Fusion 4dr Sedan

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

20000 mi Drivers window would not stay closed when using auto close feature. Regulator had to be replaced under warranty. 
6000 mi window bounce-back. Update: The window bounce-back problem on the 2017 Ford Fusion Energi happened very intermittently; since it seemed to go away on its own by the time I last had the car, I never took it in for repair.  
3300 mi Sync system, radio, and satellite failed. 
66000 mi

US $300
3G modem update to 4G 

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2017 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

2200 mi 12v battery discharged overnight. Car would not start in the morning. Same problem occurred in the first 2017 Fusion Hybrid we owned (which the dealer bought back from us under our state's lemon law). 
34000 mi Passenger side front window limit switch malfunctioning. When attempting to close the window, the window would reach the top of its travel then fully re-open. 
1000 mi 12 volt battery in this Fusion hybrid repeatedly discharged. Car would not start. Dealership and Ford tech support unable to correct after 30 days with vehicle in their possession. Car was replaced under state "lemon law." 

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2016 Ford Fusion 4dr Sedan

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

10000 mi When phone is paired to system and climate control is set to auto, thumping noises can be heard thru phone. Repair was not attempted, Cause unknown 
14700 mi Due to background noise from a faulty microphone, the hands free is almost useless. Three trips to dealer, still not resolved. New part ordered, not installed yet. 
43000 mi

US $50
Rodent damage 

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2016 Ford Fusion 4dr Sedan

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

33000 mi Audio system speakers making odd noises when system was powered off. System reset reflashed. Seems to be ok 
25000 mi The Driver Information System reported a bad SD card for the GPS system. GPS fails to function. Dealer found that the SD slot is bad, and part is on indefinite back order. 
25000 mi This was a repair done to replace the SD Card Slot for the navigation system. It was faulty and the navigation stopped working 
35500 mi The battery died and needed to be replaced 
62000 mi nav. SD card, 
74400 mi battery was dead. 
28000 mi driver seat motor replaced 

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2016 Ford Fusion 4dr Sedan

turbocharged 178hp 1.5L I4 6-speed shiftable automatic FWD

23560 mi Drivers side mirror - mirror would continue to ''search'' when you unlock the car with the remote or press one of the Presets (for seat and mirror the mirror would go to full extent of range before it settled either facing the sky or the car). 
32000 mi Driver's side memory mirror stopped functioning. Driver's door module replaced under warranty. 

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2016 Ford Fusion 4dr Sedan

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

16500 mi Screen on center console went white. does not display rear camera either radio information. Radio and voice commands works. 
30000 mi

US $300
Replace Ambient Air Temperature Sensor. Wires were cut by someone who worked on vehicle before I purchased from Hertz. Lower air dam was reconnected with sheetrock screws instead of OEM type screws. 
9900 mi Passenger Bag sensor failure (Passenger Bag OFF light ON) /  Passenger power seat motor assembly (Seat turn right when moving to the front and motor sounds rough) Replace defective battery Replacement done under current warranty 

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2016 Ford Fusion 4dr Sedan

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

52000 mi Update modum 
56000 mi My Ford Mobile will not update. Modum was replaced but after three trips, the dealer could not repair and Ford instructed dealer to not perform any additional work. Two year old car and Ford is unable/unwilling to repair. 
58000 mi My Ford Mobile fails to update. Attempted repair but failed. Fourth trip to the dealer, fourth failure. 
49852 mi

US $42
Window regulator in front passenger side stopped working only allowing the window to only go half way up. 
7000 mi Speaker sounded blown. 

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2015 Ford Fusion 4dr Sedan

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

Instrument Panel control switch on steering wheel worked intermittently 

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2015 Ford Fusion 4dr Sedan

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

7700 mi Driver window quit working 
11000 mi

US $33
Permanently repaired window problem from previous repair. This was expected as the previous visit they did not have the part in stock and did a temporary fix to hold until this visit./ 
36000 mi

US $130
I got ready to leave for work, and the car was completely dead. I had to use the emergency lock to open the drivers door, and nothing woke up (the screens were all dark). It had worked just fine less than 8 hours earlier. 
44500 mi Battery failed due to age. 
16740 mi nav system shorted out; module replaced 
5300 mi computer that talks between dash panel and main CPU was not transmitting any data. car would run but nothing on the dashboard would. windows and door locks ok. all gages radio and a/c controls out. 
28000 mi Car had no power after sitting 2 days, doors would not unlock as ke slot is not exposed. dealer had car a week could find no problems. 1 item replaced by recall. 
137000 mi backup camera image distorted while everything else displays fine on the screen. Wire harness in the trunk that connects to the camera was loose. no apparent damage or broken pieces on the connector, just loose 
11300 mi Right front seat belt was locked in the stored position, and would not pull out. Tech attempted to free the belt, but electronics would not allow it. Belt assembly was replaced. 

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2015 Ford Fusion 4dr Sedan

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

32000 mi Charge Ring lost a segment. (It has four lit segments indicating charge.). Purely cosmetic issue however. 
7000 mi Nav system volume suddenly sets itself to full volume, then impossible to turn down until car is restarted. Frequent Cross-Traffic alert faults. Cooled seats do not function as advertised. Technicians failed to resolve these issues. 
24000 mi 12V battery died 
24000 mi 12V battery died (again) because the battery replacement from December was a dud. 
18000 mi Battery stopped holding a charge, dealer replaced it. 
27000 mi Could no longer communicate between car and app. Modem needed software update. 
29000 mi Replaced cabin heater. 

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2015 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

1860 mi CD player stopped reading CDs. No CD music. All other audio functions OK. 

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2014 Ford Fusion 4dr Sedan

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

37000 mi

US $85
Dead Battery 
74000 mi

US $2150
Driver side would only blow cold air. The climate control unit had a broken door so couldn't flip to hot air. Needed to pull out dash to replace $1100 part. 
19000 mi

US $40
Driver-side headlight would flicker when turn signal was engaged. Dealer mechanics corrected the issue with a BCM update. Nearly a year later, the issue has never returned. 
2500 mi Sync voice activated mic not working. 
4000 mi Radio stopped receiving HD broadcasts. 
7000 mi HD radio stopped receiving HD broadcasts. 
32000 mi Car would not start, battery dead, nothing was left on, and battery successfully recharged. 
40300 mi

US $100
AC compressor clutch "blew up". Replaced with entire new compressor, included a recharge. 

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2014 Ford Fusion 4dr Sedan

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

5000 mi Heated Steering wheel failed to get warm when activated. Heating controller replaced. Left headlight flickers when blinkers activated. Replaced BCM and reprogram to fix problem 
9000 mi Collision System disabled (sensor blocked). System worked fine after car restart. Service tech found code c1a67 and performed horizontal aim procedure. 

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2014 Ford Fusion 4dr Sedan

turbocharged 178hp 1.6L I4 6-speed manual FWD

23900 mi Air conditioner was not blowing cold. Dealer replaced parts. 

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2014 Ford Fusion 4dr Sedan

turbocharged 178hp 1.5L I4 6-speed shiftable automatic FWD

44000 mi

US $100
Power door lock remote not working 
34000 mi Also, radio would not turn on during one trip. They thought the chaffed wires were responsible, and it hasn't happened again. 
5000 mi The car wouldn't start because it wouldn't recognize any of my keys. The remote start function also failed. Body computer and wireless control module were both bad. 
6000 mi After the body computer and wireless control module were replaced, the car still didn't start after 1 day. Wires were pinched between the instrument panel and firewall, creating a short on the wake up signal wire. 

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2014 Ford Fusion 4dr Sedan

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

36200 mi

US $42
Driver's power mirror would not adjust left-to-right. Dealer charged $100 to diagnose the problem and wanted an additional $280 for the repair. I declined the estimate. I purchased a genuine Ford power mirror motor for $40 plus tax -- about 30% less than what the dealer wanted for the same part -- and spent half an hour installing it. 
62400 mi

US $200
Battery was replaced to address a slow cranking issue. 
19600 mi Change oil prompt will not reset, dealer is unable to repair. 
68200 mi

C $135
Replaced battery. 

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2014 Ford Fusion 4dr Sedan

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

12000 mi Driver's headlight flickers when headlights and turn signals on. Replaced BCM. 
5300 mi Musty smell when first turning on AC. Ambient lighting color would revert to ice blue after car was power cycled. Dealer installed new software to fix problem. High Definition (HD) stopped working in the radio function. Dealer installed new software to fix the problem. 
34000 mi Center console kept rebooting itself continuously. Dealer replaced the APIM under warranty. 
20000 mi Charging light port ring replaced under warranty 
5000 mi Seat motor started sounding different. Worked perfectly fine but I didn't want it to later go out after the warranty was over. I had the auto-easy-entry/exit option on. Ford replaced it the same day for free without hassle. 

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2014 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

25000 mi The 110V 3-pin socket was too loose, did not hold the plug in. The socket had to be replaced. 
40000 mi The 110v AC outlet had problems with inverter. Dealer claimed this was due to plugging in an appliances rated more than the maximum the outlet can handle (150W). I do not recall using an appliance rated at more than 150W. Dealer fixed the issue under warranty. 
59520 mi

C $350
120 V outlet in the rear cabin wasn't working when I plug in a laptop despite wattage within 150W limit (laptop was only 90W) also the power lumbar stopped functioning on the driver's seat 
49000 mi Cruise Control button on steering wheel stopped working. The button was replaced under warranty. 
113000 mi

US $397
The left front headlight burned out, necessitating a removal of the entire front end of the car (a design "feature" of all 2013 and beyond Fusions). I had both headlights replaced (might as well) and also changed the oil (it was due). 
68000 mi

US $34
Nav, hvac, audio display keeps shutting off and shoeing error message. Dealer not able to diagnose or replicate intermittent issue 
31000 mi Daylight sensor for automatic headlights was not functioning. 
35000 mi 120V AC outlet in back was broken and not providing power to plugged in device. 
20000 mi Passenger side blind spot module defect. 

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2014 Ford Fusion 4-door

6-cylinder hybrid automatic 2WD

36700 mi

US $202
Back up camera went out 

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2013 Ford Fusion 4dr Sedan

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

30000 mi New window modules 
12000 mi I had left the vehicle at the dealer while on vacation HD radio and climate control many under the remote start menu was not accessible 
19000 mi Interior lighting would not retain settings. Required "recalibration," maybe a software update? 
37000 mi

US $100
Outside mirrors not fully functional. Diagnosed as problem with driver-side mirror switch. Replaced under extended warranty with $100 deductable. 
22000 mi Right rear door actuator failed open and had to tie the door shut with a rope. Caused road noise. Showed dealer, part was backordered for 2 weeks.  
22800 mi Dealer repaired rear door actuator. 
16740 mi One Touch up windows needed reprogramming 
21700 mi Remote key fobs not working, Reprogrammed body control module 
13000 mi Computer malfunction prevented car from starting. This has happened twice, requiring a computer reboot. The first time I had it towed to a dealership. The most recent time, a roadside tech unhooked and reattached the battery, fixing it. 
12000 mi Both wing mirrors start moving on their own up and down and back and forth. Memory positions for seats and mirrors gone. Ambient lighting defaults to default color. 
38000 mi

US $100
Evaporator unit was flaking and large amounts of dust was entering the cabin. Cost would have been about 2000.00 but this was covered under a Ford Extended Warranty 
10000 mi

US $60
Interior ambient LED not working. Dealer said repair made to wiring connector under warranty. 
51000 mi

US $140
Battery replacement 
9000 mi Sour musty smell coming from a/c vents when hot outside. BAD for first minute, then gets much less noticeable. They sprayed deodorizer. Worked 1 day, smell came back. Many on the forums report this same problem. 
20000 mi Strong mold odor upon start up. TSB found by me to replace ac housing. 
36000 mi Temperature control system failed.temperature setting could not be changed. 
71000 mi

US $250
Tire Pressure Sensor Fix 

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2013 Ford Fusion 4dr Sedan

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

3000 mi Nav system unable to display sirius traffic correctly Nav system did not display traffic with Sirius package. 
45700 mi

US $1100
Repair damage from animal chewing wires and insulation 
Earlier - car just failed to start. totally dead, 
4340 mi Have taken to dealer 2x as MyFordTouch has bugs, the first time it reset itself and nothing could be found, 2nd time they reprogrammed the system. Had same problem the same day I picked up from shop. They will now contact Ford troubleshootin 
5580 mi My Ford Touch still acting up, shuts off A/C when nav data entered, sat radio won't change station. 
8680 mi UPDATE - apologies to Ford. I have figured out why the climate control shuts off and the radio changes entering NAV or phone numbers on the touch screen. The screen is slanted and I was brushing my hand on the controls causing the symptoms. 
29100 mi The push button starter fails to engage the starter intermittently. It usually works after a try or two, but I wanted to get this issue on record before the warranty expires (Jan 2016) so it was taken to dealer and they could not replicate. 
73780 mi

C $260
Power door locks stopped working. I pulled the fuse (hard to get at) but it was fine. Took to dealer and they had to reprogram radio module, charged 1 hour plus shop supplies and tax no parts required. 
Navigation has problems not showing correct location. 
7900 mi Navigation position errors. Driver's door speaker inop. Navigation position error. Ford Corporate requested different dealer look at it. 
9000 mi Remote start could cause the car to die and not restart. Reflashed computer with update. 
10000 mi Navigation position errors never fixed. Turned out it was because I had winter tires on the car that were a slightly different diameter, and the MFT nav system uses wheel speed sensors to infer current position from last known GPS position. 
8000 mi DIAGNOSIS ON SIDE MIRRORS RESETTING ON THEIR OWN, TRUNK OPENING ON ITS OWN, 
45000 mi

US $50
Mirror position switches stopped working correctly; replaced switch module in driver's door. 
51000 mi

US $350
The driver's side LED tail light failed. The outer red light would not light. The brake and directional (located in the center of the tail light workded fine). Had to replace the entire assembly because it is an LED tail light. The Driver's side BLIS is not working. I need to take it to the dealership to get the ECU reflashed. 
7500 mi All of the warning lights went on in the car (ABS, airbags, traction control, hill assist, 911 assist, etc.) while I was driving. Took it in the next morning, and they said it was unsafe. Turned out to be a busted Restraint Control Module. 
30000 mi Odor from ventilation system. Replaced evaporator cover per tsb 
31000 mi Evaporator cover replaced 

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2013 Ford Fusion 4dr Sedan

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

25000 mi Horn malfunctioning. Appears to be vibrating against another component, causing a garbled/harsh noise. 
6480 mi Replaced faulty battery. 
13000 mi Wet carpet on pass side floor due to condensate leak from cracked condenser box under the dash. Service dept applied some more silicone. 
5000 mi

US $20
Missing a parking light bulb...in the passenger side head light assembly. Need to remove entire front bumper skin to replace so it probably took more then 10min. Assembly process missed installing it. 
74000 mi Changed oil and filter, also replaced the air filter. Got the hood latch light fixed, was a issue after some body work from nearly 2 years ago...just a bad wire. 
5955 mi Wiper motor failed 
12900 mi Musty/moldy smell from A/C vents. Dealer performed TSB to correct. 
19220 mi Express up and Express down for both front windows would not work all the time. Taken to dealership 3 times (so far). They "re-initialized" switches but still having problem. They are not replacing switches...yet! Not happy with dealership. Delay in starting. Periodically I will turn the key to start the car & there will be a short delay (2-3 seconds) before the car turns over. Taken to dealership twice now but they are unable to replicate. Will try to record it with cell phone 
13000 mi Driver side window stopped working. Scheduled an appt and it started working again a few days before service visit. I still brought it in and they found no issues. They just lubes the windows. 
27000 mi Needed a new battery 
4000 mi Airbag lcd displayed that airbags were off. It happened while I was driving. The message disappeared the same day.I brought it to dealer and they did some software update but still couldn't tell me what was the problem. 
4840 mi Keyless entry keypad defective 
8780 mi Airbag light would come on intermittenly over August and part of September. Sensor checked, no codes found in history. Hasn't happened again Once again the hood ajar light would stay on this is the second time since June. Hood ajar sensor would come on every time the car was started Sensor was replaced, hood was aligned and adjusted problem solved. 
31000 mi Outside Temperature Reading way out, showing 30 to 40% higher than actual outside temperature. Dealer won't fix. 
33294 mi

C $100
DLR not working properly. Need new relay. Will be repaired once relay is available 
12700 mi Power window inoperative 
16000 mi Climate controls went haywire temporarily. 
35000 mi Pre-mature battery death. I suspect parasitic drain could be a component. Car was driven regularly for 2yrs then I didn't drive it a week and the battery was flat. Jumped it, drove an hr, flat again the next day 

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2013 Ford Fusion 4dr Sedan

turbocharged 178hp 1.6L I4 6-speed manual FWD

38000 mi

US $200
Turn signal cancels were too sensitive. Dealer said the problem was not hardware, but required a small reprogramming of the software to fix. 
76000 mi

US $200
Battery failure. Not low and needed replacement, but full and immediate failure. 
6500 mi passenger side door lock not functional Driver heated seat not functional. Update: replaced control module but still not working after 3 attempts. Problem with heated seats resolved. Entire IP replaced (my ford touch system). 
18000 mi AC makes gurgling sound. Passenger side carpet wet. Found leak on compressor line and condenser connection. Drain holes plugged. Replaced seals and recharged system. Rear 3rd brake light 3 LEDs stopped working. Replaced entire 3rd brake light assembly. Radio on/off button stopped working. My ford touch IP replaced to correct issue. 
58000 mi Airbag light turned on occasionally. Bad driver side seat belt buckle. 
71000 mi

US $20
Washer fluid pump stopped working. Replaced pump. 
26000 mi Car was cranking slow, and a low voltage warning came up on the touch screen. I dropped it off after working hours, and the car was finished the next afternoon. A new battery was installed. 

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2013 Ford Fusion 4dr Sedan

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

8800 mi The Sync system bluetooth connection to smartphone stopped working along with both remote keyless entry fobs 
20000 mi airbag fault light. airbag control module was on backorder. 
31500 mi Tire pressure sensor failed, reset Both key fobs stop unlocking and locking doors...Took car on Christmas Eve, could not get resolved as Ford was closed. Fixed in January by pulling then reinserting a fuse to reset system. 
34000 mi The dealer did a TSB in regards to the key fob problem I had on Christmas Eve...Also requested a oil consumption test be conducted with this current oil in the car.... 
3000 mi I informed them at that time that the clock loses 15 min. a month. Clock is on the audio screen. No fix attemped. They just reset it and told me to keep track of it. 
95000 mi

US $90
AC recharged and seals replaced 
86000 mi

US $187
Wiring harness for window switch was pinched during previous recall work. Rear windows did not work from master switch. 

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2013 Ford Fusion 4dr Sedan

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

29000 mi 12v battery went completely dead. 
2000 mi A/C would not turn off when pressing A/C button. FCIM was updated to latest calibration to address issue 
12000 mi Memory seats did not work with Intelligent Access key fobs. TSB 14-0039 was applied to fix the issue with a reprogramming of the Body Control Module (BCM). Fuel gauge would drop too much after filling car. TSB 14-0219 updated the IPC (Instrument Panel Cluster) software to fix this issue. Ambient lighting would sometimes change color by itself back to the default color. TSB 14-0175 was performed to update the APIM (Sync Module) to fix this. Turn signals would cancel too quickly during certain types of turns. SSM 44909 called for an update to the SCCM (Steering Column Control Module) to fix this. Steering wheel radio buttons would periodically be inoperative after calling Sync Services. SSM 45012 called for an update to the SCCM to fix it. Since the SCCM was already updated as part of the turn signal issue nothing else was needed. 
13900 mi Dead 12V battery, replaced under warranty 
16000 mi A telematics module regulating battery charge required replacement with a new module with newer firmware to eliminate an issue where the car was discharging its 12 volt battery (Fusion energy only issue) 
17000 mi Telematics system (remote start, GPS location, remote unlock, etc.) no longer working in many locations. Ford elected to use a 2G cellular network that is being retired by AT&T in most of the US. All 2013-2016 Fords will now fail in 2017. 
20000 mi 12v battery still discharging. Traced problem to charging the cars traction battery using 110 power exclusively. Using 220v or simply driving with the ICE engaged would prob. resolve this issue. 
2700 mi Module Control Charging system replaced. 
39200 mi Auto up windows did not work for front doors. Re-programmed DDM and PDM modules with latest calibration from Ford and solved problem Go-times not functioning. Re-flashed the FCIM with latest calibration from Ford. Fixed issue 
21300 mi 12 volt battery would not hold a charge. 
50000 mi

US $152
Replace 12V battery 
60000 mi

US $170
Reprogram AC module and touchscreen display to make AC & heat functional again 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

6500 mi front doors window one touch worked intermittently 
8000 mi

US $20
A/C would not turn off when pressing A/C off button, compressor stayed on, FCIM was reprogrammed with latest calibration from Ford Front & rear parking sensors would sometimes sound muted, especially in cold weather, module was reprogrammed with latest calibration from Ford Blind Spot System would have periodic failures, module updated with latest calibration from Ford Navigation would show car off of road, driving in a field, etc. GPSM was reprogrammed with latest Ford calibration per TSB Frequent "Battery Saver" messages about low 12V battery SOC, dealer claimed that they could not replicate the problem 120V outlet in rear seat was loose, plugs would fall out. Outlet was replaced Navigation POIs do not work using steering wheel buttons on right dash screen. Ford is aware of the problem but does not have a fix at this time. Dash will periodically reboot while driving. Screens go black and speedometer goes to 0 then reboots. Dealer "could not replicate" the problem. Engine Block Heater use caused an error code to be thrown. Reprogrammed per TSB. 
88000 mi Recall 14E02 - Powertrain Control Module(PCM) needed reprogrammed. rnRecall 14S21 - Airbag Warning Indicator required replacement of the Restraints Control Module. 
1700 mi SYNC stopped working. Dealer replaced a sterring column module 
10000 mi Sync system does not display POI info on right dash screen 
10000 mi RT dash display will not show POIs This is s Sync issue 
50000 mi

US $87
Right front passenger speak rattling. Replaced speaker. 
51000 mi

US $30
Driveside headlight out. Changed both driver and passenger side. 
100000 mi

US $1400
Small battery located in truck was 8 years old and needed replacment 
16000 mi Vehicle repeatedly enters "battery saver mode" during the cold winter months. Unfortunatley, the day that the technician looked at the car was warm outside, he could not replicate the issue. The service advisor told me to come back in winter 
29400 mi Main battery still failing to properly charge, vehicle enter battery saving mode during cold weather. Dealer was again unable to replicate the problem, despite the photos that I took of the error message. 
27000 mi A/C would come on after I turned off system; touch screen too sensitive i.e. seat warmer would suddenly be on when I didn't touch control, etc. Dealer ordering module part. 
3000 mi All auxiliary electronics failed at once due to a bad ground: ABS, traction control, camera, radio, nag 
44000 mi

US $180
Air conditioning stopped working due to loose wiring 
73000 mi

US $75
Rear passenger 110V outlet stopped working, was replaced 
90000 mi

US $125
Battery will not charge - replaced 
9300 mi When dealer installed shift knob they did not hook it up correctly so it needed to be re-done. The Grade Assist button on shifter didn't work after swap 
12000 mi 12 V battery was not being charged properly due to short duration of driven trips 

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2012 Ford Fusion 4dr Sedan

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

35200 mi 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 

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2012 Ford Fusion 4dr Sedan

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

51460 mi

C $125
Replaced driver side seat base heater 

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2012 Ford Fusion 4dr Sedan

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

124000 mi Battery began dying during my courier route. Had it replaced the next day. 
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. 
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 
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 
8680 mi 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 
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. 
18000 mi Lots of corrosion on terminals, car won't start. Replaced battery under warranty. 
59000 mi

US $100
Dome lamp not turning on when RF door opened. Faulty door latch. Latch replaced under Ford extended warranty. $100 deductible. 

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2012 Ford Fusion 4dr Sedan

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

70680 mi

C $50
Door lock stopped working and replaced driver front door handle. 
50000 mi

US $140
battery check indicated dead cells and needed to be replaced 
104160 mi Dual heater control fixed and blower fan replaced. 

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2012 Ford Fusion 4dr Sedan

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

37000 mi car received new battery under warranty 
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. 
133000 mi

US $12
Right license plate light housing had rust/stopped working. Found housing cracked. Replaced housing with Ford part. 

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2012 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

31000 mi Noisy heater/AC fan assembly. Dealer damaged bumper, forgot to fix the problem I brought it in for. 
21200 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. 
79000 mi

US $89
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. 
46000 mi

US $200
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. 
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. 
175000 mi

US $350
Replaced A/C compressor, condenser, & filter/drier and flushed system due to failure. 
60000 mi

US $90
New battery 
34000 mi Battery terminal corroded into two pieces. All maintenance done, replaced harness under warranty. 
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. 
164300 mi

C $20
Headlight bulbs replacement, tail light bulbs replacement. Burned out. 
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. 
24000 mi No cool air present. Mechanic states "impact hole in condenser. Cannot warranty". Taking to another dealer for second opinon 

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2012 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

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. 
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. 
25000 mi 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. 

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2012 Ford Fusion 4dr Sedan

97000 mi

US $300
Left window went out in 2016 and I finally got it repaired. Needed a new window motor. 

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2011 Ford Fusion 4dr Sedan

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

13300 mi Sync system stopped playing USB music. System was reset by disconnecting power to fix. 

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2011 Ford Fusion 4dr Sedan

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

2980 mi Lumbar support not working. 
14880 mi Replace cabin air blower motor. Warranty paid 

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2011 Ford Fusion 4dr Sedan

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

1700 mi APIM module for SYNC system determined defective at earlier visit, dealer ordered part, was replaced. Seems to be functioning so far. 
80000 mi Driver Seat Heater element was replaced. 
55700 mi

US $5
Replaced, for the 2nd time, right rear turn signal light. 
32900 mi Battery corrosion around battery terminals. 
29000 mi Same problem battery terminal corrosion. Recleaned battery terminals. 
60000 mi

US $100
Replace blower motor 
80000 mi

US $1500
Issue with air conditioning, believe it was the.blower motor and module 

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2011 Ford Fusion 4dr Sedan

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

54300 mi

US $150
Battery lost a cell. 

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2011 Ford Fusion 4dr Sedan

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

99000 mi

US $735
A/C compressor failed resulting in complete replacement of unit as well as flushing of complete system and evac/recharge 
105000 mi

US $194
left front headlamp assembly required replacement due to a faulty socket 
9920 mi External temperature sensor broke, car showed -33C all the time. 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

16000 mi ECU failed while driving the car just shut off and would not turn back on. 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

110000 mi

US $400
HVAC controls quit working, entire control assembly in dash had to be replaced. 
4200 mi Sync system stopped accepting voice commands. Dealer updated Sync software. 
40800 mi

US $95
Ticking noise when blower fan on low setting. Dealer first tells me 300+ for assy replacement, then finds TSB to replace fan only. Sadly out of warranty, so out of pocket. 
32200 mi

US $100
car needed multiple jump starts. battery needed replacement. Also did the recall repair on the throttle body. 
95800 mi

US $175
Battery life low - did not replace 
90700 mi

US $400
Battery cable was corroded and entire harness had to be replaced. Unable to just replace the positive battery cable. 
34040 mi

C $200
Battery was replaced. 
32000 mi TPMS Failure 
54000 mi Fan assembly squeaked when running. 
60000 mi

US $75
Replaced compressor pulley due to high pitched whine. 
58280 mi High pitched whine - the car almost sounded like it had a turbo kicking in - which it did not. Known issue. Probably something to do with the alternator. 
106000 mi

US $100
Blower motor intermittent. checked connections, still failing about half the time. 
113000 mi

US $45
Blower motor resistor and control module failed. Contacts overheated and continuity was intermittent with increasing failure frequency. Dealer wanted 200 for part NAPA 175 Amazon $45. Works good now, not sure how long it will last. 
28000 mi Heater fan made high pitch noises. It was replaced under warranty. 
35000 mi

US $150
Battery gone bad and burned out signal light. 

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2011 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

58200 mi

US $290
The battery shorted out after 4 months of non-use sitting out in the Texas sun. 
91760 mi

C $75
Just replace a burnout headlamp. Two were replaced since it is recommended to replace two together. 
75000 mi

US $400
Window Regulator replacement 
65005 mi

US $130
Replaced factory 12 V battery. 
89000 mi

US $120
Replaced battery. 

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2011 Ford Fusion 4-door

6-cylinder manual 2WD

28500 mi air would start cold then turn hot 

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2010 Ford Fusion

Engine not specified

8000 mi I had the reflash done on the transmission and it did not work with my car. Whenever you would shift between gears, I had to wait for 2 to 3 seconds for it to go into gear. If by chance you hit the gas it would slam into gear. The auto climate control was reprogrammed and it still did not work. Would blow out cold air as soon as car started, didn't wait for engine to warm up. 

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2010 Ford Fusion 4dr Sedan

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

11200 mi

US $101
Battery wouldn't hold charge. This is the second battery I have had to replace. Next time I won't go to the dealers' for battery. 
49000 mi

US $450
Compass display always at North. New module ordered and installed. 
61000 mi

US $1080
Leak in steering/AC condenser - unit replaced 
34000 mi HVAC blower/motor was making a twittering sound, sometimes very high pitched. Dealer replaced blower. 
47000 mi

US $111
Battery wouldn't hold a charge when car was off for more than a couple of days. Diag showed bad battery. Factory battery warranty ends with car warranty. Replaced with new battery from Ford (which has a nice long warranty). 
87000 mi

US $75
Battery not holding charge. Prorated and replaced. However, new battery only has remainder of previous battery warranty. 
4000 mi Owner noticed that drivers window would not go down. All other windows worked fine. Fix was to reset the software. The auto-down motor experienced a heavy load due to frost sealing the window. This will become a problem for Ford. 
29700 mi rear tail lamp burnt out. 
42000 mi Airbag light was on intermittently due to a pinched/damaged wire. 
62700 mi

US $50
Airbag light turned due to short. Replaced wire harness 
72100 mi

US $50
Airbag warning light on. 
88600 mi

US $1000
Battery was not holding a charge. Battery was brand new when I bought car, however the dealer installed a under powered battery when I bought it causing it to fail after two and a half years. Installed newer more powerful battery. Driver heated seat element burned out. Replaced heating element under extended warranty 
85000 mi

US $75
Tire sensor replaced. 
90000 mi

US $850
Tire sensor failed and replaced 
104000 mi

US $350
Blower motor and temp sensor resistor replacement due to increasingly frequent loss of AC 
105000 mi

US $300
Intermittent A/C. Found to be a loose wire connector. Problem returned within 48hrs 
105000 mi

US $297
Loose connection in harness/connector causing interment blower operation, problem still agree acted by bumps. 
112000 mi Intermittent AC blower operation. 
122000 mi

US $400
AC blows intermittent , shuts down, then blows again for 15sec to 2min. Replace AC temp sensor . 
126000 mi AC blower low output, warm air. Replace cabin air filter, replace blower motor (warranty) 

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2010 Ford Fusion 4dr Sedan

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

18000 mi Low tire pressure sensor had to be replace when the light on the dash continuously said I had a low tire 
14880 mi Noise from front vent. Diagnosed as "door actuator" problem. Part ordered. 
15500 mi Ordered vent actuator was installed. 
28520 mi Backup camera intermittently not working. They were unable to diagnose the problem as it worked while they had the car. It has not failed again since then. 
32860 mi Passenger airbag sensor was malfunctioning. It was replaced. 
34260 mi

C $50
Battery would not hold a charge. It was replaced. 

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2010 Ford Fusion 4dr Sedan

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

43500 mi A/C is out at 43,000 miles, there is a leak in a line and will cost too much to repair. Car is out of warranty... 
46000 mi AC out. 
54000 mi

US $450
The positive battery cable was corroded and needed to be replaced so I could replace the battery as well. Turned out the positive cable was actually one of the main wiring harnesses and had a book time of 3 hours to replace. This was a real shocker. On most well-designed vehicles the cable is a single cable going to the starter VERY POOR DESIGN 
44640 mi bad automatic driver window mechanism (would make weird noise) motor and assembly replaced by the dealer 
9000 mi air conditioning would freeze up and not work. Fix not yet verified. 
11000 mi Replaced SYNC module. 
31620 mi The blower motor was squeaking loudly. Dealer ordered a new blower motor, and replaced the noisy blower motor a week later when the part came in. 
75020 mi

C $150
I replaced a squeaky blower motor.  
90520 mi

C $150
Battery would not hold a charge, had died a few times in the past but a jump start seemed to fix it but just wouldn't hold a charge anymore, so had it replaced at independent shop. 
112000 mi

US $505
AC not working. 
15300 mi Replaced keypad on drivers door due to one of the 5 keys being dim. 
27000 mi Replace blower motor due to chirping sound. 
37100 mi

US $100
Battery would not charge, replaced. 
41700 mi

US $23
Replaced backup warning speaker. Old speaker made high pitch sound instead of normal sound. Bought off of ebay. 
47400 mi

US $200
Replaced leaking AC hose from compressor to condensor. Recharged system. 

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2010 Ford Fusion 4dr Sedan

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

80000 mi Battery would be flat unless run at least every two days. Charging system, battery, etc. checked OK by dealer. Dealer wanted $100 min to check further, which I refused. Traded car elsewhere. 
30000 mi

US $166
Faulty tire pressure sensor. 
60000 mi

US $3
Replaced rear turn signal bulb. It took much longer than ten minutes. I had to remove much of the inner lining of the trunk just to get to the tail lamp. 
72000 mi

US $130
Sync system stopped working, no longer paired with cell phone. After four hours of attempting to reprogram the system, it was determined that the "module" needed to be replaced. Part was ordered but has not yet arrived. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

23560 mi

C $50
Changing the fuse of the 12 volt plug. 
5000 mi No start or Hard start. Extra ground strap with a capacitor added per TSB. 
30000 mi Smell from AC. System deodorized and fan replaced. 
1000 mi front turn signals did not work, smart junction box replaced 
36000 mi battery not holding charge, replaced buzz in left speaker when engine on during usb 
56000 mi

US $50
Follow up to previous repairs. Still hesitating, swapped out other sensors to no avail. Finally found that the wiring pigtail connector Motorcraft WPT1241 was under strain and many of the wires were fraying. New harness has strain relief. 
72000 mi Tire pressure sensor fault, light on dash. Tires fine. Mechanic said battery in the tp sensor might be bad and that the other batteries might go out. Repair seemed too costly at this time. 
76000 mi

US $100
TMPS sensor went out and was replace when new tires purchased. 
12000 mi Sync system required a system download so that the USB port and phone would operate. Took 40 minutes for the two downloads. No problems since the work. Sync system required a system download so that the USB port and phone would operate. Took 40 minutes for the two downloads. No problems since the work. 
33900 mi Air coming from ducts would stop even though fan blower was working after a couple of hours on the highway. Took car in for TSB on AC problem. Reflashed the AC programming. Seems to be working normally now. AC stops blowing cold air after extended highway driving. AC system reflashed according to TSB. No problems since then. 
78200 mi

US $280
Alternator voltage regulator failed and would not keep the battery charged. Serpentine belt changed during alternator replacement. 
93000 mi

US $130
Battery would loose a charge with little electrical load if engine wasn't running. Battery was 66 months old and the original factory battery. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

40000 mi SYNC System reset 
47000 mi

US $75
Electric window on drivers door malfunction. Computer module reset required. 
18600 mi Auto-dim mirror activates at night but fails as vehicles approach. Eventually, I have to point it away to avoid blinding. The mirror passed all testing. The issue is solved by rotating the mirror upside down so the sensors are higher. 
44640 mi

C $600
Key fob failed (lock/unlock/trunk/alarm 
55180 mi

C $553
Battery replaced as it only tested at 102 Cold Cranking Amps. 500 is the expected standard Licence plate light bulb was burned out. Testing revealed the assembly was cracked and corroded and needed replacement 
42000 mi Blower motor made chirping sounds. They replaced it, under my extended warranty for 100$. 
57000 mi

US $100
Speed control problem; no acceleration - throttle body control unit was replaced. 
68000 mi

US $237
system was freezing up. found there was TOO MUCH refrigerant in system and bled off 3 lbs. 
60000 mi

US $100
At 45k miles, February 2013 the seat heater fried out and got really hot burnt the seat. Never repaired. 
114000 mi

US $120
Worn o-rings on compressor were leaking coolant. 
175000 mi

US $25
Ground wire to headlights needed replaced 
34000 mi Recirculation motor chirping. Removed/replaced. 
77000 mi

US $15
Sync and Parking sensor speaker replaced. 
37000 mi

US $210
Battery test failed. Battery was replaced 
40300 mi

US $100
Parking brake switch. Switch had been triggering a "Packing brake engaged" warning when parking brake was actually released, disabling cruise. 
68000 mi

US $1000
Driver's seat replacement due to a heating element failure 
28520 mi Cd player not working 
50000 mi driver side seat heater stopped working after extremely hot temp,have not repaired yet 
66800 mi Radio sync cd stop working intermittently 
32000 mi no cold air 
46000 mi

US $98
new battery purchased at 45,000- very early failure i have since disabled the feature that keeps headlight on when starting and leaving the auto. also disabled some of the cabin overhead lites to reduce load on battery. 
122000 mi

US $1200
Dash was pulled to replace defective air conditioner sensor $800.00 
130000 mi

US $200
Tire pressure sensors replaced. Ordered VDO sensors from Rock Auto and had my mech install. 
26000 mi Front passenger blower fan was 'clicking'. Replaced part, still clicking... have to take it back in for another repair... 
59000 mi

US $100
Passenger side vent fan broken - had to be replaced. 
34000 mi Passenger airbag sensor under seat went bad - would not detect passenger and would disengage airbag. Passenger door speaker rattling 
48000 mi Battery died twice in a week with no obvious source of drain. Well within warranty. Had it replaced. 
83000 mi

US $179
Washer fluid pump failed. Dealer replaced the entire fluid reservoir and pump assembly. 
2170 mi TSB to replace engine ground strap 
4340 mi Car would not start on first or second try. However, this was an intermittent problem that would happen about once per week so hard for mechanic to determine the problem. Installed grounding wire. 
7440 mi Low tire pressure warning saying "TIRE SENSOR FAULT". No reason given but problem fixed by re-set of software I was told. 
59520 mi

C $250
Car was dead one morning. Dealer load tested battery and was OK. Re did test after road test. Battery failed. New OEM Battery installed. 
10000 mi air bag light came on. Connector was making bad connection, connector was replaced. 
23000 mi Blower motor fan in HVAC makes constant clicking like a baseball card in bicycle spokes. Mechanic discovered damaged fan blade. Parts ordered however the fan motor was on "National Backorder" until recently. Still waiting for parts. 
27500 mi

US $200
Half of the cost was for replacing a tire pressure monitor. Half was for replacing an A/C blower that was starting to click. 
12000 mi Air conditioner became intermittent during a long trip. Turns out that the problem was known issue, and there was a TSB: A/C SYSTEM LOSES AIR FLOW/INOPERATIVE— TSB 09-18-11 They re-flashed the computer, and that fixed the problem.  
24200 mi

US $325
Air conditioner was not working. Fuses, relays, refrigerant were fine. Dealer found a failed Evaporator Discharge Air Temperature Sensor; quoted $25 for part and $760 for labor. Screamed bloody murder at dealer and Ford, who covered 60%. 
62000 mi

US $1400
A/C sensor failed again. Cheap part, lots of labor to replace. 
2900 mi TSB installed to correct occasional hard starting that seemed to occur only when raining or very humid. TSB was successful. 
35340 mi

C $60
Window wipers stopped working. dealer disassembled and inspected motor and got them working. Ice build-up was the cause 
8000 mi Starting difficulty--car would at times crank 3-4 times before turning over. Problem is with an electrical short connected with the car's starter--solved by installing a "ground strap." Ground strap installed. 
138580 mi

C $200
tire pressure sensors not working 
99820 mi

C $425
Lost power assist steering. 'Advance Trac' and 'Service Power Steering Now' lights on. Dealer replaced both rear TPS sensors in tires!! Power steering restored. 
40000 mi Battery still has to be jumped after towing 4 wheels down. car cannot start if left in neutral and key left in accessory for a short period of time. Dealer say they don't know why. They tried it on a new Fusion and the same thing happened. 
32000 mi Battery was run down. Dealer checked it and said it was OK - did not need replacement. 
8000 mi Had a starting problem. There is a campaign on this, and it involved adding a new ground. 
59000 mi Steering wheel controls for phone, etc. not working. Module part was over $800, and total bill about $920. 
4000 mi bad ground wire replaced with new type, problem on first cars built 
78800 mi

US $180
Recharge air and replace pully Motor on air conditioner vent 
84000 mi

US $130
AC has now been taken to dealer to refresh computer. I found there was a technical notice and gave dealer number. They did a refresh for $130 and that seems to have resolved the problem. 
32000 mi

US $56
replaced factory battery as it would not hold a charge 
57000 mi

US $60
HVAC fan was squeaking like a bird. 5min, $60, 3 screws and one plug and I put a new one in. Super easy so don't pay someone to do it. Seems to be a common problem 
120000 mi

US $55
Airbag light on. Connections were checked, one was loose. Oil change. 
172000 mi

US $65
Head light 

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2010 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

62200 mi Speaker module for rear parking aid and cross traffic advisory intermittent. Speaker module replaced 
29000 mi Instrument panel would occasionally have an uncommanded reset to the default mode. Software TSB performed. 
58000 mi

US $62
TPMS sensor had failed and was replaced during new tires installation 
94000 mi

US $25
Speaker module for back-up and cross traffic alert failed. 
29000 mi Normal battery needed to be replaced after only 2.5 years. 
48500 mi Changed the tail light bulb. I did take more than 10 minutes to do it because the whole taillight needed to be disassembled. 
48300 mi

US $300
Fixed broken speedometer 
84898 mi

US $151
Replaced battery 
7440 mi One integrated key fob quit working, key had failed, dealer replaced under warranty 
29000 mi Dash on hybrid reset occasionally. The mpg would reset and dash displays would go to factory defaults. 
41700 mi Battery was found to be defective and replaced. It was not under warranty. 
111000 mi

US $115
Display for hybrid was not showing braking energy being saved back to battery. Turned out to be a display problem only. Software fix worked for a little while, but now doesn't work again. 
76100 mi TPMS fault. All tires at correct pressure. Worse when cold or wet. 
81500 mi

US $300
Replaced 2 TPMS sensors 
10000 mi Sync system sent text msg to my phone stating I had a serious brake issue (no dash warning illuminated). System had old code that went active, dealer had to call Ford for instructions, reflashed. 
80000 mi

US $500
Ignition switch replaced 
91000 mi

US $300
Battery failed 
100200 mi

US $100
Cross traffic alert warning system. 
8000 mi Speedometer stopped working. Needle stayed at 0 MPH regardless of the speed of the car. 
80000 mi

US $260
Headlight went out on trip, went to dealer in AL. Other headlight dimmed due to age, replaced. Said fog lights out, they work now but wonder if that was mistaken (pull out knob, not obvious). 
107000 mi Stranded at airport after trip, due to 12V battery. It was within the 36 month full warranty and replaced at no charge. 
140000 mi LED tail lights started growing dim on one side. Lincoln dealer (this is actually a Mercury Milan) said both sides were affected and replaced at no cost. 
41300 mi

US $110
12V battery failed completely, without any advance symptoms. Replaced with a Bosch battery of greater capacity. 

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2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

32000 mi radio sync trouble plagued seek gets stuck on sat and getting a blip in signal playing as if I hit an overpass which interrupts signal. Phone syncing up hit or miss po'ed. Not getting the right answers from the dealer. 
42000 mi

US $128
Replaced dead battery 
37000 mi

US $55
HVAC blower motor emitted high pitched squeaking noise; I replaced it myself. 
12000 mi horn blew on right side of steering wheel but not on left side. 
16120 mi

C $140
dead battery, 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

13000 mi backlight out on radio button, Replaced Radio. The radio that was installed to fix the backlight problem had bad reception. A new radio was ordered. Ordered radio was installed. 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

80000 mi

US $90
Replaced battery 
55860 mi

C $100
Weak battery under stress. Replaced to avoid problem in the winter. 
10500 mi Clunking sound in the front passenger door. The speaker replaced. 
154000 mi

US $21
Climate panel was failing: the temperature control knob produced weird results (cold-warm-cold-hot). I replaced the climate control panel with a part from ebay. 
46000 mi

US $422
Speedometer broke. Speedo partially inoperative, operates at random/erratic times, transmission has erratic shift pattern. EEC Test, code P0720, tested and replaced OSS (Odometer Speed Sensor). Part cost = 101.82, Labor cost = 311.81. 
29000 mi a/c compressor noise that occurred when accelerating from a stop, could not replicate. 
10000 mi No heat was coming from heater/defroster. Dealer replaced a blend door actuator. 
36700 mi

US $20
HVAC motor squeaked. Replaced motor with a new unit. Solved. 

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2008 Ford Fusion

Engine not specified

99000 mi

US $100
Ac would ruin my gas mileage by >8 mpg Rpm dropped below 500 when running it and would almost stall my car out. 
102000 mi

US $100
Air conditioner was leaking out into my floor. 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

96957 mi

C $100
Ajar switch in the rear (driver side) dysfunction was starting the alarm when the car was very cold so i had to refrain from opening this door during the last winter to get time to research this on the internet. The repair imply to change the whole module for around 400$. It cost me 100$ to find out that the general info on the internet was bad and i ordered the wrong switch. Only the dealer has the good information about this specific module. So for the moment, i am waiting to observe more evident trouble. It manifest only in extreme cold weather. 
110000 mi

US $600
Drivers seat heater replaced 
115550 mi Airbag replaced 
121000 mi

US $80
Blower motor squeaking / replaced 
21300 mi Auto-dimming mirror sometimes does not dim from auto headlights to rear of car... dealer claimed it is working to spec. Do not know how it was tested; test might have been invalid, i.e. light applied up close. 
29000 mi Battery cable and battery replaced under warranty due to serious corrosion at the positive battery terminal connector 
10000 mi Starter "catches" sometimes when turning the key. Makes a short "zing" noise. Couldn't replicate it at the dealership nor could I in the parking lot. They were very good and told me to bring it back if it repeated. 
41000 mi

US $50
Replaced headlamps. 
162700 mi

US $70
Leaking A/C required recharging. 
176000 mi

US $750
Evaporator core was leaking, and replaced evap temp sensor as a preventive maintenance item. 
22000 mi Analog clock began running between 5 and 15 minutes fast every 24 hours. Also, hour hand was falling behind and it became impossible to tell the correct time. HVAC auto climate control head unit does not start up if left overnight during cold weather. Unit resets to "Off" and also loses stored temperature setting. Unit has to be manually switched back to "on" afetr starting the car. 
8000 mi Radio had popping noise.  
20000 mi Part described as a module or a sensor. Dash board had to be taken off. Air conditioning would not blow cold air.  
17000 mi Very loud noise coming from the engine area. According to the dealer, they replaced a cracked air conditioning refrigerant line and the compressor, as well as the accumulator. 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

35000 mi

US $325
One of the battery cables attaching to the battery corroded and fell off. I needed to get the Fusion towed to a repair shop. 
3000 mi Blown passenger front speaker. Audiophile System. 
14000 mi HVAC blower motor squeaking. 
45260 mi

C $218
Car began showing symptoms of hard/long cranking (also SRS light would not go out after car started) 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

8000 mi One repair - to replace SYNC system master unit. Took 3 days in Feb. Unsuccessful, is likely an unresolved software issue, not hardware. 
56420 mi In the winter, the heat does not flow to the rear of the car. In fact, it actually blows cold air to the passengers in the back seat and also to the floor vent of the front passenger seat. Dealer never able to find problem. 
77500 mi Rear Defrost stopped working after handle replaced. Dealer said coincidence. Not yet fixed. 
85560 mi

C $97
Changed headlights. (It is a pain to do it on this car, so decided to take it to the dealer). Would like to see Ford make it a bit easier for the owner to access these small things. 
1200 mi Blower motor would squeak at low speeds. Found the fan bearing to be out of balance. Had to get the heater core blower fan and motor replaced. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

11000 mi

US $200
TPMS malfunction 
8060 mi After a cold soak ( -25 C) the heater / Air Conditioner computer stays blank and looses it's memory. The heater will not work until a manual selection is made. Ford is working on the problem. A fix not available yet. 
10540 mi When cold soaked, the Air Conditioner / heater computer loses its memory and the heat will not come on when command start is used. Ford is working on a fix.  
14880 mi auto dimming mirror intermittant. replaced 
12000 mi Sun Roof retraction bar snapped, causing roof to twist and remain in up-right position. Entire unit needed replacement. 
30100 mi Battery died 2.5 years after purchase. Dealer towed car, gave me rental for weekend, and replaced battery. No charge, just inconvenienced since occurred about 20 miles from home & dealer. 
27280 mi Replaced noisy (ticking) HVAC blower fan. 
37000 mi

US $200
Car failed to start. jump started by AAA. Car driven to dealer who replaced the battery and tested systems. Told battery was 'Worn out" out of warranty replacement. Approx $150 out of pocket cost Clicking noise from heater fan. Parts replaced under extended warranty. $50 decuctable and rental car reimbustment. 
51000 mi

US $200
Chirping sound from heater fan previously replaced 1 yr ago re-occured and the shop replaced the part again. 
82083 mi

US $694
Recharged A/C system 
88000 mi

US $120
Power door lock actuator for the front passenger door failed. Bought a new one for $120 and replaced it myself. 
63840 mi

C $50
replace headlight. 
92380 mi

C $170
replace tire pressure sensor 
92380 mi

C $420
Power window switch repair. 
35000 mi

US $100
CD's stuck in multi disc changr Blower motor noisy when cold 

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2007 Ford Fusion

Engine not specified

109000 mi

US $750
sensor for air conditioning needed replaced. Cost $100 to evaluate. Part was $18. Entire dashboard had to be removed to replace sensor which is known to short out. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

43000 mi driver side heated seat stopped working. control does light up for about 1/2 second but then shuts off. 
64700 mi

US $125
Airbag light came on and stayed on. Electrical system acting "funny". Turns out the battery failed to hold a charge and once it was replaced the airbag light stayed off and things seem normmal again. 
113000 mi

US $200
replace sensor in dashboard that was preventing the AC compressor from running 
122000 mi

US $120
airbag light comes on and stays on when starting engine. engine cranking slow. Needed a jump once because battery died on a short trip. Replaced battery and all is well again. No airbag light with new battery. 
71300 mi Heated drivers seat not working  
92380 mi

C $400
Drivers side heated seat not working 
98600 mi

US $1200
The module in the instrument cluster broken in order to get the panic button to the key fob to work had to replace cluster. 
104000 mi

US $95
Radio display was not working needed soldering Dealership wanted to replace radio for $600 including labor. 
115000 mi

US $140
Brake Switch Transmission would not shift 
13000 mi The air conditioning fan speed is less than the amount specified by the user, and it flutters up and down in speed several times per second (never reaching full speed). 
14000 mi The air conditioning fan speed is less than the amount specified by the user, and it flutters up and down in speed several times per second (never reaching full speed). The front right window makes a crackling noise (like crumpling paper) whenever it is moved to the closed position. I felt that the air conditioning fan speed was still reduced, even after the repair from the previous week. Dealership held car overnight, then compared its air flow to another similar car and decided that air flow level was fine. 
7000 mi TSB reported repair for Audiophile rear speaker pop when brake pedal is applied. New ground for rear speakers was connected and no problems since. 
148000 mi Power window motor, passenger side. 
175000 mi Window regulator, driver's door. Radio replaced due to screen burning out. 
227000 mi

US $15
Power seat motor failed. Replaced with junkyard part. LCD display quit working on radio about 6 months ago. 
270000 mi

US $12
Both front marker light sockets melted. Replaced with junkyard parts. Both front marker light sockets melted. Replaced with junkyard parts. 
292800 mi

US $117
Positive battery cable separated and started arcing to the battery and nearby metallic components. 
296000 mi Compressor and blower motor failed. Cost of repair exceeded vehicle's value. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

102920 mi

C $25
Evaporator tray sensor fried, had to replace. Cheap part, but have to remove dash to access. 
79440 mi

C $102
Battery died'stoped holding its charge 
18600 mi

C $200
car 2x would not start 
42160 mi

C $500
Electrical -running lights wouldn't turn off, locks wouldn't work. 
13640 mi A/C stinks, dealer tried fixing 3 times, still stinks. Probably won't buy another Ford, after always owning them. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

10000 mi Chirp through rear speakers when the brakes were applied. A known problem with the premium sound system. Repaired using instructions from TSB. 
61380 mi Speed sensor has failed consequently the speedometer and odometer are not working. Also, the engine light is on (assumed to be related since there are no other issues). It will take 2 months to get the part due to high demand. 
61380 mi

C $420
Speed sensor failed in April but part didn't arrive until Sept. Part was $280 and installation was $140. No changed in odometer due to odometer not working. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

67000 mi

US $40
Light assembly illuminating the rear license plate died. replaced -- cost under $40. 
29000 mi power door lock assembly in front passneger door stopped working,  
17000 mi Popping noise coming from speakers whenever brake pedal was pressed. TSB 07-13-1. Successfully repaired. 
19000 mi Fan cycled on/off at high speed with AC running. Found TSB and replaced defective fan. 
95500 mi

US $100
Replaced battery 
160000 mi

US $350
window regulator 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

182000 mi

US $480
Resistor connector melted which caused blower motor to not run. 
39000 mi

US $332
Since new this car has emitted a diesel-like clatter from the engine that becomes more strident with activation of the a/c compressor. A NY based dealer diagnosed a faulty A/C compressor and replaced same including all pulleys. 
130000 mi

US $700
The smart junction box failed requiring a complete replacement. This can only be done by a dealer because it has to be programmed to the car. 
66000 mi

US $1300
Compressor needed to be replaced. 
137000 mi

US $250
Window regulator fail 
5000 mi Reflashed electronic temperature control to change the operation of the temp up and down buttons. Used to scroll when you hit the button. Now you have to hit it one time for each degree of change. 
19220 mi Power window regulator faulty. 
315000 mi Airbag recall 
27000 mi Still Waiting on Dealer to Fix Ignition switch that thinks the key is always in it. 2nd Visit, still no satisfactory results. 
33000 mi Fixed ignition switch. 
47350 mi

US $5
Right rear turn signal went out. Replaced both rear signals. 
81460 mi

C $175
Remote start control module replaced 
8060 mi

$5
Back left turn bulb 
8370 mi Automatic Climate Control sensor and A/C blower motor relay cover by warranty 
124000 mi The wiring on left headlight is malfunctioning. Headlight goes off and/or wiring shorts out from time to time. 
128000 mi

US $35
the connector on the headlight burned out. replacement of connector. 
12000 mi changed a swith in the AC 
25000 mi Blower motor clicking. Blower motor replaced. 
44000 mi CD player stopped working again. 
46000 mi Previous stereo replacement defective. Replaced with a new stereo which has since stopped working :( Update: turns out they only had to reprogram the ACM, which they failed to do in August. 
80000 mi

US $150
Had to replace the ac sensor at 60,000 miles. Lost all AC and only blew hot air. Sensor was behind firewall and horrible location and access was very hard - bad design. American companies suck. 
123000 mi

US $40
license plate light fixture, state inspection item. 
68820 mi

C $80
Check battery light randomly illuminated/went out twice while car was being driven with no accessories running. Dealer reported no codes, load and voltage tests OK, visual inspection of wiring OK. 
91860 mi LF amber light does not light when activated for turn signal. No fast blink/error message and mechanic confirmed light is not reaching socket on blink. Other lights unaffected. Possible 'control unit' malfunction. 
90920 mi

C $100
Ford OE replacement battery low in 2 cells and discharged after approx 100k km / exactly 5 years. Replaced with Costco house brand, no issues. Orig battery wouldn't jump, hold a charge. 
110980 mi

C $550
Front left turn signal inoperative. Replaced smart junction box from wrecker, same year and trim. Fault with instrument cluster caused Ford passive anti-theft system to lock up and required a battery cable to be pulled for the car to restart. Problem also caused erratic gauge and MIL light behaviour until the car warmed up. 
78000 mi

US $150
Starter and battery replaced 
117000 mi front turn signals went out and one marker stayed lit shorted to power the smart junction block needed replacement at $1,100 
76000 mi

US $122
Motor and Regulator for the Right Front Passenger Door went out (became inoperable). Ordered the parts and replaced. Note: ordered Regulator did not fit properly. Forward rail upper bolt hole did not align and new hole was drilled in the alum panel. 
300 mi CD player died, it wouldnt take any CD's so had it replaced. 
124500 mi

US $40
A/C not cool. Add refrigerant 
123700 mi

US $50
Airbag light had been on intermittantly. When brought to the dealer for diag, the light had gone out but it retained a code of a problem with the pass seat wiring. Decided to keep an eye on things and no further work was done. 
32000 mi Auto temperature control sensor for AC failed. Replaced under original factory warranty. This was the first repair of any kind on this car. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

148000 mi

US $500
Electrical connections for the clutch pulley of AC system had to be replaced. System charged. Also a new front driver side fender liner and side marker light from a previous incident. 
104000 mi

US $1300
Starter. 
32000 mi Driver's seat heater element burned out and was replaced. 
92000 mi

US $40
replaced side mirror control switch  replaced side mirror control switch 
92000 mi

US $40
replaced license plate bulb. took more than ten minutes, I'm a bit of a novice. 
100000 mi

US $130
It ended up being the battery. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

217700 mi

US $100
Battery 
58360 mi

C $100
Front turn signals stopped working. Had to replace and reprogram the smart junction module. 
166000 mi

US $162
clear air bag lamp and check system 
208000 mi

US $370
replace alternator 
13000 mi CD player would not function. 
59000 mi

US $800
Sensor in a/c system failed. Required removal of dash assembly to service. 30 dollar part, balance was labor. 
15000 mi steering wheel radio functions wouldn't work correctly 
24500 mi Driver side lumbar support on the seat broke. Replaced by dealership under warranty. 
70000 mi

US $467
Evaporator temp sensor was replaced, which involved removing the console and dash. 

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2006 Ford Fusion 4-door

6-cylinder automatic 2WD

11000 mi Had to replace the left rear turn signal bulb. 

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See TrueDelta's information for all Sedans
See TrueDelta's information for all Ford models.

Ford Fusion Electrical 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.