Ford Fusion Ford Fusion

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Ford Fusion repairs by problem area

Engine (24%)

Transmission and Drivetrain (11%)

Brakes and Traction Control (8%)

Suspension and Steering (7%)

Electrical and Air Conditioning (27%)

Paint, Rust, Leaks, Rattles, and Trim (14%)

Other (8%)

Chart based on 1671 repairs.
See TSBs and recalls for the Ford Fusion.

Ford Fusion engine repair cost distribution

$2500+ (6%)

$1000 - $2499 (5%)

$500 - $999 (19%)

$100 - $499 (62%)

< $100 (8%)

Chart based on 145 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2015 Ford Fusion 4dr Sedan

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

17000 mi Coolent level was always dropping and car had some issues with stalling after ignition. Check engine light also. Dealer found coolent leak inside engine. Warped engine upper block. Replacement upper portion of engine on order. 

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2015 Ford Fusion 4dr Sedan

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

3000 mi Hose sensor fitting seeped and shorted out sensor. 

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2015 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

4000 mi Engine was running rough, then check engine light came on. Diagnosed as Camshaft position sensor error. Took to dealer, they replicated error, ordered and replaced part. 

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2014 Ford Fusion 4dr Sedan

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

12000 mi Bad fuel pressure sensor. 

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2014 Ford Fusion 4dr Sedan

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

19000 mi Gas tank filler system needed to be replaced 

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2014 Ford Fusion 4dr Sedan

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

26000 mi Water pump was replaced 
34000 mi Engine vibrating at idle, both in gear or in neutral. Chaffed wires in dash were suggested as the culprit. Fixing them didn't fix the vibration. 

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2014 Ford Fusion 4dr Sedan

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

102000 mi

US $100
Fuel pump busted or fell off. 
12000 mi Engine lags @ times after stopping for traffic light.MECHANIC DROVE VEHICLE APPROX 20 MILES WITH ME AS RIDER IT DID NOT OCCUR. 
15000 mi Engine icon came on. 1st reported as gas tank pressure leak. replaced a seal on gas tank. Engine icon came back. 2nd reported as wiring problem. 

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2014 Ford Fusion 4dr Sedan

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

33300 mi Charge port for Hybrid battery was replaced 
4000 mi Reflash computer per TSB to remove check engine light. 
35700 mi seal in the gas door was was allowingfumes to escape. 
11000 mi Emissions sensor replaced 

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2014 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

6000 mi When the car runs on the gas motor it vibrates thru the steering wheel, gas pedal, brake pedal.And makes a lot of noise from the engine. When it goes back to electric, it has no vibration & no noise. Dealer said this is normal for the hybrid 
15000 mi When the car runs in gas mode only the engine is very noisy and has a lot of vibration coming thru steering wheel, center console etc. The tech had me drive a new Fusion Hybrid & it did the same thing. Plan on getting rid of car ASAP. 
22700 mi

US $45
Gas engine vibrates & makes excessive noise. Runs fine when in electric mode. 
35000 mi R&R timing chain cover due to oil leak. 
13700 mi Check engine light was on. Diagnosis was done but no fault was found. The check engine light was reset. 
10000 mi Defective cam shaft sensor Part was not in stock. 

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2013 Ford Fusion 4dr Sedan

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

9000 mi 16 gallon tank would not accept more than 12 gallons when showed empty. 
13000 mi Gas tank would not fill completely. Tank replaced. 
11300 mi TSB 13-06-03: Gas Tank only allows 12-13 gallons on fill (16.5 gallon capacity). Requires tank to be replaces as well as computer reset. Vehicle started leaking fuel, rock got stuck in o-ring and created a gap. The seal was replaced. Gas tank was replaced and SYNC was reset, however I filled immediately after leaving dealership and with 11 miles to empty I was only able to put in 13.084 gallons. 
7000 mi Oil leak. Ended up being front engine cover being loose from factory. 
84000 mi

US $150
Car was hard to start immediately after refueling. It ended up throwing a check engine light with a code P1450. I changed the evaporative canister Purge Solenoid located under the hood and it fixed the problem. 
11300 mi Fuel tank and fuel pump replacement 
3000 mi Lose bolt on the tailpipe, dealer tighten the bolt. 
9000 mi Fuel tank does not fill completely. The Ford representative re-calibrated the gauge cluster but the vehicle is still having the issue.  

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2013 Ford Fusion 4dr Sedan

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

6000 mi Engine quit while traveling on freeway, total system failure in all sensors, emergency brakes engaged. Not resolved until October. 
5580 mi Recall for Fuel module. Parts initially not available. Finally done after fuel started leaking, and codes thrown. Still a fuel leak when filling car, but not as bad as before. Plugged vapor tube no parts available, have ordered them. 
5980 mi

C $140
Fuel module and gasket replaced under warranty and was subject to recall, but was also leaking fuel when filled, so vapor tube was also repaired. This seems to fix the leak but I have not driven the car since Dec 1 as I am in Hawaii. 
8680 mi I was driving from Canada to Palm Springs when the check engine light came on and 'check fuel inlet' error message came on. It also dumped fuel again under the car when filled. It was the same problem repaired in Nov, repaired again in PS. 
17360 mi Third time to dealer for fuel leak when filling car. Fuel delivery module recall was done 1st time, did not solve problem, parts ordered and installed. Worked for a while then leaked again. Parts ordered and replaced, now parts ordered. 
19860 mi Car has leaked when filling gas tank since new. Third attempt to repair now seems successful. They removed fuel tank and said some line was not connected which caused the leak. Since repair I have had no problem with fuel leaks. 

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2013 Ford Fusion 4dr Sedan

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

8060 mi Engine would not warm up after running for a lengthy period of time, heater would not blow warm air. Dealer inspected and said this was normal, nothing was done. They are wrong. 
14880 mi Car was running rough, white exhaust from tailpipe. Dealer replaced spark plugs. 
18600 mi Dealer had to replace catalytic converter as engine light kept coming on, replaced under warranty. 
21080 mi Coolant sensor replaced 
19840 mi Over heat when cold temperature. -32'c 
62000 mi

US $50
a purge valve on the purg assembly dg9z-9d289-g 
30000 mi Stalls; shortly after warm start like it runs out of gas. Fix:Service ticket says; detected fault code P008B low fuel line pressure, traced fault to the fuel pressure sensor. Replaced return fuel line, sensor only available with fuel line.... 
27000 mi The bottom of the piston was cracked and thus needed to have the entire short block replaced on the engine. 
13000 mi Bypass coolant valve. 
7300 mi Engine coolant level went down to min mark. they tested for leaks but didnt find anyhing. They topped it and and it is on min mark again. I honestly dont know what is wrong with it. 

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2013 Ford Fusion 4dr Sedan

turbocharged 178hp 1.6L I4 6-speed manual FWD

38000 mi

US $100
Engine coolant bypass selenoid failed. Threw check engine light. Covered under manufacturer extended warranty and only cost me deductible ($100). 

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2013 Ford Fusion 4dr Sedan

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

24000 mi Car is using oil...Had to add oil since last oil change...Dealer checked for leaks, found none...Noted the dates and mileage I added oil.... 

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2013 Ford Fusion 4dr Sedan

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

17000 mi Check engine lights began to appear, car felt as if running on 3 cylinders, nearly stalling. Dealer consulted Ford and applied various TSBs and fixes. Car declared fixed and returned, though the car failed outright a few weeks later. Gasoline engine failed completely. Dealer worked with Ford and eventually discovered that the cylinder head has been improperly manufactured. The engine was disassembled and reassembled a number of times and the head and internals replaced. 
7700 mi Plug-in charge ring lighting failed 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

5500 mi Check engine light due to ice build up in fuel filler inlet Check engine light, was found to be a bad Purge Solenoid, was replaced under warranty 
7500 mi Stuck Port Valve 
38700 mi Failed sensor causing check engine light 
12000 mi Inverter coolant system leak at cap. 
5500 mi The Check Engine light came on and as per the vehicle health report, it was something to do with the fuel system pressure. Dealer replaced a valve for the same. 

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2012 Ford Fusion 4dr Sedan

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

16120 mi I had an episode of spontaneous acceleration when going very slow up a driveway. Scary situation with small children in the vehicle. 
65000 mi

US $100
Oil pan gasket leaking. Covered under Ford PremiumCare ESP. $100 deductible. 
21300 mi the cooling fan bearing was squeaking and the blower fan was chirping both parts replaced 

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2012 Ford Fusion 4dr Sedan

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

36600 mi Recall for carb. I had a few instances where when I accelerated it bogged down that I was unsure of the cause... when the recall came in it seemed to fit. 
16000 mi The car has a constant vibration and hard shifts with high RPM going more then 20 miles an hour, A rattle appears as I accelerate. Ford mailed a letter identifying the Vin to possible throttle body contamination. Recall in Oasis 
104160 mi Engine smokes & rattles for 5 sec. They said noting was wrong. I sent them a video of engine noise no luck yet. 
47500 mi Throttle body was replaced under expanded warranty. The Fusion was exhibiting severe drivability issues. 

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2012 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

70880 mi

C $715
Belt squeaking when engine is cold. Water pump leak contaminated the belt. Replaced belt and tensioner and water pump. - 
24000 mi Emissions-service engine light came on. Followed instructions for driving 3 cycles then cold starting to see if light goes out. it didn't. Mechanic said the Emission filter cartridge had to be replaced. 
32300 mi false reading from check engine light sensor 
36300 mi

US $100
vehicle entered 'limp home mode'-most likely caused by throttle body failure, a known defect, with Ford extended warranty for part. it was cheaper for me to replace part myself, rather than pay ford to diagnose the problem 

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2011 Ford Fusion 4dr Sedan

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

78000 mi

US $300
OBD sensor port went bad. Found out during emissions testing. 

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2011 Ford Fusion 4dr Sedan

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

16740 mi car had a rattle at speeds over 100 kms,heat shield for the cat. conv. was to close to conv. and was moved slightly. this repair took test driving and 2 shop repairs to get satisfaction!! 

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2011 Ford Fusion 4dr Sedan

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

55300 mi Car was displaying check engine light related to evaporative emissions problems. Related to pending recall for defective evaporative purge valve. Mine was stuck open. 
60500 mi

US $360
Throttle linkage replaced 
12000 mi Erratic shifting 
57000 mi

US $50
O2 Sensor triggering check engine light 
60000 mi

US $50
Emissions sensor 
69700 mi

US $50
Throttle body replaced 

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2011 Ford Fusion 4dr Sedan

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

58000 mi Throttle body sensor failure. Loss of engine throttle control. Engine went to idle at 70mph. The throttle body was replaced. 
34100 mi Throttle defect, car died several time when it was running. Very dangerous especially when you were in the middle of an intersection. Many same problem reported. Warranty repaired. 

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2011 Ford Fusion 4dr Sedan

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

95300 mi

US $1150
ECM required replacement due to complete failure 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

21880 mi wiring badly protected, fuse of the engine blown a few times. Had to redo a part of the wiring. 
16000 mi Fuel cap was not properly closing could smell gas. We had to have the gas cap replaced. 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

112000 mi

US $200
Replace fuel pump. Replace valve cover gasket. 
118000 mi

US $220
Water in valve sensor. Air in cooling line 
129000 mi had to replace tensioner pulley and drive belt 
63000 mi "Check fuel fill inlet" warning comes and goes intermittently, due to faulty sensor in capless fuel fill system. Did not repair. 
78000 mi

US $200
Replaced faulty fuel filler neck 
58000 mi Emission problem. Capless gas valve leaking. Seems to be fixed for now by cleaning and fiddling with the cap. 
42700 mi Catalytic converter gone bad. Warranty replacement. 
44700 mi

US $150
idler pulley replaced. 
86000 mi

US $50
Wiring fault with check engine light. Ended up being a Bad O2 sensor even though code indicated wiring fault. 
1240 mi TSB for intermittent delayed engagement into gear. 
1000 mi Thermostat stopped working, car overheated and check engine light came on. 
47120 mi Recall for the fuel tank that caused an engine warning light to appear in the dash. 
6000 mi MIL Light on (check engine) - Codes P052, P052 - TSB 11-2-10, cleared codes. 

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2011 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

53320 mi

C $100
check engine, sensor check engine, sensor broken 
38840 mi

$300
The display showed "high motor temp". It was the motor wiring was shorting. The wiring was replaced. 
86800 mi Oxygen sensor (upper) problem 

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2010 Ford Fusion

Engine not specified

16000 mi Took the car in with transmission problems. Updated the software. 
55000 mi

US $400
Car went dead on the highway with no warning. Took them several hours to diagnose the issue but ended up replacing the throttle body. 
8000 mi Had the coolant bleed twice and it did not work. 

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2010 Ford Fusion 4dr Sedan

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

90000 mi

US $850
Vibration, worn transmission mount, replaced 
98000 mi

US $1600
Vibration worsening with time. 3rd trip to dealer to diagnose. Replaced all 3 motor mounts. Runs like new. 

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2010 Ford Fusion 4dr Sedan

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

21000 mi

US $10
Tire pressure light on with no tire pressure problems. Engine surging--fixed due to TSB 

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2010 Ford Fusion 4dr Sedan

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

22000 mi

US $100
Problem with car going into limp mode. Concerned it was linked to previous transmission issue. Replaced throttle body and sensor. 
75020 mi

C $150
An emissions purge valve had to be replaced. I was able to do the work myself. 
42500 mi

US $140
Car was stalling out from rolling starts or coasting such as crossing railroad tracks!!! Dealer diagnosed as throttle body, and I fixed it myself in 5 minutes due to out of warranty. New seems to have helped transmission slipping/bucking. 
46000 mi Car had issue starting after sitting around without being used. Would barely turn over then sputter to life and knock real loud. 
23000 mi Replace valve cover gasket. 
39000 mi

US $150
Car went into fail safe mode on highway. Bought new throttle body on amazon and replaced it myself. 
51000 mi Replace valve cover gaskets and grommets due to them leaking oil. 
52000 mi Engine was still leaking oil after replacing valve cover gasket. Oil leak found by front cover, crankshaft seal and valve cover gaskets/grommets were replaced. 
61000 mi

US $125
Car was making harsh almost grinding noise when accelerating in low gear. Notice upper engine mount was leaking. Replaced it myself after watching Youtube video (wasn't too hard, but need jack and breaker bar). Car runs great now. 
9000 mi Engine would hesitate and feel like it was going to stall out. tach would drop 
52080 mi

C $455
Throttle body control unit went bad on HWY and although I still had powertrain warranty it is not covered. 
53000 mi Driving down the highway the car went into Limp Mode. Turns out the Throttle Body had to be replaced. 
73000 mi

US $200
Check Engine Light. Required to replace fuel filler tube and reprogram PCM. Known issue via Published TSB. 

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2010 Ford Fusion 4dr Sedan

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

128000 mi

US $460
O2 sensor failure code, replaced part 3 times so far and every component in this subsystem. Still coding and check engine light remains on. 
33000 mi Check transmission valves and reflash TCM 
59000 mi Check Engine Light and Code revealed problem with Variable Cam Timing (VCT). Dealer replaced solenoids in VCT under warranty. 
16000 mi Sudden loss of throttle control and power, engine and trabsmission went into failsafe/limp mode. Service engine light on, code indicated throttle body unit failure. TB was replaced. Acceleration from rest and shifting now much smoother 
6000 mi Automatic transmissiion slippage, early shifting. hesitant shifting, erratic shifting  
19660 mi Throttle body replaced. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

1000 mi Intermittent no start. Engine turns over but will not start. Dealer pull codes and none were found. Dealer could not replicate the problem. 
2000 mi No start, issue unresolved. 
16000 mi Whining noise coming from engine. Whining noise increased and decreased with engine RPM. Belt Tensioner Pulley replaced. 
57700 mi

US $347
Throttle Body replaced. 
43400 mi check engine light on,evap code 
38440 mi

C $233
Changing the vapor valve 
55000 mi

US $37
car bucking during acceleration after manual shift completed. No codes or check engine light. shop cleaned throttle body sensor. This did not help, rechecked, decided to replace sensor. Waiting for part, unavailable for 4 weeks. 
55500 mi

US $300
Follow up to June report: after 4 weeks, throttle control unit became available. Part=$200, labor=$100. repair complete 
76000 mi

US $100
Fuel fill inlet warning/check engine light ton. Mechanic checked systems found no problem. reset warnings. Warning on and then gone 2 more times. car shows no symptoms 
100000 mi

US $200
serpentine belt tensioner 
65060 mi

C $800
Bearings in the idler and other pulleys worn out. 
5000 mi Air trapped in the cooling system causes a fluid swishing sound as car is accelerated when cold or engine idling for 1 minute or more. Occurs less frequently when at operating temperature. Still exhibiting the sound of coolant flowing through the heater core. Ford is providing the dealer with another procedure to attempt a fix. Car will be at dealer during the week of February 8, 2010. 
6000 mi Dealer contacted Ford on air trapped in cooling system. Dealer ran tests as requested by Ford. Ford sent field engineers to evaluate car and recommended complete engine replacement. Since repair, coolant sound is no longer present. TSB 09-19-1 to correct intermittent/no start done. No problem starting since completed 
109000 mi

US $140
After a dead battery, the wrench light would come on and the engine would not go above 900 RPM. Tried the relearning process for the throttle body but it didn't work. Replace throttle body and did the relearn process. It fixed the issue. 
68200 mi

C $250
CEL code for evap sensor triggered. Sensor itself was defective and replaced. 
31000 mi Noticed a rattle from engine bay during startup and at clutch engagement point in 1st and reverse. Tech road tested and found airbox had become unseated from pressure fit mount. Tech reseated airbox. Hopefully it does not return. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

25000 mi Engine makes rattling/whirring noise at 35 & 45 mph. Took two drives for servicemen to hear it. Because computer did not detect problem, nothing broke, no repair made. It is a standard noise heard on their rental cars - no problem. WHAT?! 
27150 mi I took it AGAIN for whining engine at 35&45 mph & getting louder. Took 2 drives for them to hear. First they said "Normal noise" but I said it was NOT normal. They worked w/ Engineers and replaced pulley/tensioner. ALL GONE! Under warranty After only 9 days back from the shop, my car emergency engine lite went on & engine vibrated, even in Park. After tow to shop, svce says it was a bad throttle body, like many Ford Fusions. Was replaced with brand new one under warranty. 
108000 mi

US $700
Warning Light for emissions system - catalytic carbon filter 
43400 mi Sept 20 34590km Temperature guage up on "H" and then goes back down to normal when I stopped the car. Check coolant, it was very low. No check engine light luminated. Problem: hole in radiator. It takes 4 day to ship rad and fix it. 
68820 mi

C $280
Pulleys for drive belts were humming. Upper and lower tensioner pulleys replaced. 
73160 mi Check engine light on and 'Check Fuel Fill Inlet' reading on gauge warning. EVAP leak code found and smoke test required to find leak. 
94860 mi Recall for problem with throttle body. 
104440 mi

C $250
Tension pulleys making noise. Needed to be replaced. 
45880 mi

C $160
Serpentine belt was worn and needed replacing. Replaced by backyard mechanic using an AC Delco belt 
48000 mi

US $600
Faulty purge valve caused "Check Engine" light to go on. Brought to dealer for diagnosis and repair. Exhaust system had a faulty sensor. 
13000 mi Software upgrade performed during regular oil change. Less than a week out of shop during acceleration the tachometer soared but the vehicle would not/could not engage in gear. Dealer said software update should have solved it. Didn't. 
30000 mi

US $576
Check engine light came on. Shop smoke tested system and reported EGR valve was leaking. Replaced EGR valve. 
45000 mi

US $350
I had a coolant leak. They replaced the adapter that bolts to the back of the engine. In this case back is the opposite side from the pulleys or the drivers side of the block when looking under the hood. 
11000 mi reflash ECU to fix very hard shifting -- Ford 'customer service bulletin' (aka recall-light). Seems to shift much smoother now, and doesn't throw the car forward like it used to. From passenger side of car, on cold engine moving between 1st and 2nd gears, sounds like water rushing through empty pipes; seems to go away with warmer engine. Dealer did not repair, and told me to reschedule another appt. to try again... 
40700 mi

US $100
Engine check light. Vapor valve was found defective 
57000 mi Fuel tank leak 
16000 mi Car in shop since 5 April. Delay in software and hardware parts for transmission. Hope to have car back NLT 10 May. Asking Ford for new car under lemon law. 
43400 mi

C $333
engine light on. was told EVAC valve needed replace because some over spill gas go into EVAC canister. I was suspicious as I never double fill gas. Dealer didn't give me obd code. And they said valve replaced. 
56000 mi

US $32
Car was throwing P0456 code. Internet search revealed common problems with the purge control vent valve. I tested my vent valve. It was faulty. Test took 10 minutes. Repair took 10 minutes once part had arrived. 
134000 mi

US $300
Engine and Transmission mounts were broken which caused grinding noise when accelerating. Parts replaced. 
63300 mi engine noise, actually a tensioning pulley on the serpentine belt 
48300 mi

US $110
Began with oxygen sensor, ended up with computer replacement. 
4640 mi When engine first started (after being off for more than 60 min or so) there's a noise like a surge of water through an empty pipe. Dealer says Ford knows of the problem and is trying to find a solution. Told it's a problem reported by many Fusion owners. 
9300 mi We noticed jerky shift. Friend said they had a recall notice but we did not get one. When car went to dealer they adimtted there was a recall. Transmission re-programed they said. Seems OK so far but haven't driven much since repair. 
2000 mi TSB performed to correct transmission "flaring" when cold. 
3000 mi TSB performed to correct occasional hard starting that seemed to occur only when raining or very humid. Added grounding wire. 
27000 mi Serpentine belt idler wheel bearing going bad (noisy). Quickly replaced by the dealer. 
48000 mi

US $600
Map sensor 
83700 mi

US $325
Idler pulley bearing 
51000 mi Throttle body malfunction. It was replaced under recall warranty. 
92360 mi

C $200
belt tensioner replaced 
135780 mi

C $785
fan belt replacement and damaged to part of air conditioning system. Disappointed dealer didn't recognize noise from worn out fan belt at previous oil change 
62000 mi

US $100
the throttle body went bad 
106000 mi

US $119
Water pump replaced due to mechanical failure 
44640 mi

C $600
Check engine light & "check fuel fill inlet" warning began occurring. 
48700 mi Car was whining when accelerating. Alternator pulley. 
24000 mi idler arm pulley had to be replaced 
28000 mi One Touch Ignition would not start car, needed new ground wire per TSB 
166000 mi

US $250
Squeaky serpentine belt 
35000 mi Gas gauge started dropping suddenly. There was an issue in the evap system which was fixed. 
52300 mi

US $200
EVAP solenoid was bad 
139000 mi

US $1100
Exhaust flex pipe rusted out. 
60000 mi replace smooth idler pulley and belt tensioner because of noise 
88700 mi Engine quit on busy road. Was able to restart.Fault was throttle control system failure. 
110000 mi

US $100
worn upper right side motor mount causing a noise on pulling out. Note: deka (penn) battery installed at 40k holding up. Note: use care when parking that your front bumper does not get ripped off by rebar on the parking blocks. 
120000 mi

US $100
Upper motor mount replaced. 
16000 mi Harsh 2-3 upshift when cold. Had Recall 10B15 performed, was told there was a "glitch" with that software and dealer flashed PCM according to TSB 10-21-9. 
33000 mi Intermittent 2-3 shift flare returned. Went on test drive with mechanic and reflashed PCM with latest software. So far, so good. 
59520 mi

C $250
Muffler was rubbing on the frame. Noise resonating inside the car. Dealer repaired muffler hanger. 
21700 mi

US $100
Faulty Water Pump. Covered under warranty 
25000 mi

US $120
fuel vapor vent valve 
80000 mi

US $225
I got both OBD II codes P2011 and P2012, but not at the same time. It was either one or the other code showing. I did some research, and found out that I needed to replace the throttle body. Since the throttle body replacement no codes. 

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2010 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

4340 mi No heat in cabin once engine reached operating temperature, ford fix for this problem, cooling system pressure tested, degas cap replaced, removal of air from cooling system fixed problem as degas cap was leaking. 
31620 mi Engine light came on code for o2 sensor tab for reprogam fixed issue 
51000 mi Sensor in throttle body failed. Repaired under extended warranty. 
51000 mi

US $235
Check Engine light on. Solution was to reprogram the computer. Seems weird to me too. 
80000 mi

US $260
O2 sensor, causing Check Engine light to go on and off. Replaced it. 
50000 mi bad purge valve 
68000 mi

US $387
Error P0130 02S11. Sensor faulty & replaced 
37200 mi

C $700
Required replacement of hybrid system cooling pump 
64000 mi

US $150
Brake warning light illuminated while commuting to work. pedal became mushy and there was perceived reduction in brake performance. Research indicates its a rare software glitch with the software controlling the hybrid regenerative brakes. 
85000 mi

US $387
check engine light would turn on during long highway trips (~200 mi driving at highway speeds). This never occurred during my normal 30 mile commute or short trips. Decided to pay $150 to have the computer reflashed with the latest software. 
58000 mi

US $650
O2 sensor malfunction 
500 mi Warranty repair because car had gone into "fail-safe" mode. Was an internal control valve related to the emissions controls. 
80000 mi Car suddenly lost all power on the freeway. Wife was able to limp at very slow speed on battery power a few miles to the dealer. Problem turned out to be a throttle body that had failed. Dealer replaced it under warranty. 
108000 mi

US $350
Throttle body needed to be replaced. My specific build date was not covered by recall. 
122000 mi Gas pedal stopped working while driving. Was able to coast off the road safely. First dealer found nothing wrong. Second dealer said I needed a $3K transmission, but independent mechanics said that would probably not fix it. 
82000 mi

US $250
Replaced 02 sensor 
102000 mi

US $85
Had to replace throttle body due to failure of part's electronics to properly open and close throttle valve, resulting in a wrench light. 

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2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

76000 mi

US $6
COOLING SYSTEM BYPASS TUBE LEAKING COOLANT FROM O-RING. REPLACED O-RING 
95000 mi

US $125
Thermostat bypass plastic piece leaking antifreeze when cold 
87420 mi

C $500
Radiator hose cracked from cold stress. Unfortunately the temperature dropped below -30 for more than one night. 
25600 mi

C $250
Ignition key would not work. Had to replace transceiver. Update: I have been away for 6 weeks since repair, car started okay when I got back. Now 2 days later it started acting up again. 
1500 mi A large part fell off of the engine onto the highway. I took the car and the part back to the dealer. They reinstalled the part at no cost. 
3000 mi engine has knock at idle some of the time. It is getting worse as I drive further. 
7000 mi knock comes and goes 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

17000 mi Coolant bottle would overflow when the A/C was run and the engine got hot. It was determined the cap was not sealing properly, the Coolant bottle was replaced. 
18500 mi I could feel engine vibration through the clutch pedal. The shop updated the PCM Software. Did not make a change in the vibration 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

10000 mi Engine threw a connecting rod, catastrophic failure - engine block destroyed 
29000 mi transmission light came on for a few minutes. Dealership replaced a sensor. 
45900 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 
92000 mi

US $65
The check engine light came on with a code for the secondary air injection (emissions related). Also, the vehicle would stall on rare occasion when put into gear. The diverter valve was replace and solved the problem. 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

55000 mi Valve cover gaskets reported by service tech as leaking. Replaced under 5yr/60K power-train warranty. 
76000 mi Data Link Connector for OBD computer not responding to emissions sync. Diagnosed, checked & corrected. 
48360 mi

C $1290
Repair oil leak from oil pan and engine output seal 
82000 mi

US $2000
Engine control computer replaced 
77500 mi

C $200
Oil leak change oil seal 
119660 mi

C $1675
Broken engine mount 
102000 mi 2 Rods thrown, catastrophic failure, no indicator lights, just a loud metallic sound then, BOOM. 
92000 mi

US $400
water pump failure 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

86000 mi

US $2100
PCM failed and damaged the ignition coils and plugs requiring replacemet of all items. 
20000 mi Fuel cap needed to be replaced/caused ck engine light to go on. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

74000 mi

US $120
Valve cover gasket was leaking oil. My mechanic said it wasn't major but definitely leaking. He replaced it. 
92000 mi

US $770
Oil leak at timing chain cover. oil dripping on accessory belt causing it to squeal. 
81000 mi

US $40
Temp gauge would not come up to center. Code for coolant temp out of range found (P0128?) Replaced thermostat which fixed problem. Access was difficult and not for the first-timer. 
1000 mi Fuel pump pressure bleed down overnight 
30000 mi Some type of oil cap was cracked, allowing oil to leak from engine compartment. 
69440 mi

C $375
Failure of PATS security system, required new keys and reprogramming. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

78740 mi

C $468
thermostat stuck 
93000 mi

US $145
Replace leaky valve cover gasket. 
96000 mi

US $120
intake manifold gasket 
70000 mi

US $461
Noticed an oil burning smell inside the car when not in motion, the engine warmed up & running. No visible smoke. Dealer replaced valve cover gasket & cleaned the engine. 
136000 mi Oil pan gasket. 
82000 mi

US $215
Replaced valve cover seals to stop minor oil leak. 
8000 mi Had PCM flashed to resolve the transmission's jerky shifting. Driver's side seat had cracks and was replaced. 
25500 mi I noticed the check engine light so I took my car to a dealership. They found out it was a bad catalytic converter and it was replaced under the factory warranty. 
119000 mi

US $400
Head gasket replaced 
162300 mi

US $300
Valve kit replacement 
31000 mi CEL had code read at AutoZone P2004 IMRC stuck open. Left car with dealer for a day.They acknowledged the problem but were unable to service the car that day.2 days later the CEL reset.Will wait to see if it happens again. 
10000 mi They adjusted or replaced some sensors 
30000 mi Leak from oil pan or transmission. 
41700 mi

US $900
Noise corresponding to road speed. Some sort of shaft bearing was bad. Also replace alternator, thought that was problem. 
58900 mi replace crankcase seal & coolant pump. 
71300 mi

C $400
replace thermostat 
32000 mi

US $500
Coil pack and all spark plugs 
91000 mi

US $370
Check engine reveled an air intake item needed reoplacement 
28000 mi

US $262
Replaced thermostat 
35000 mi

US $100
Bearing howling. small water leak 

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2007 Ford Fusion

Engine not specified

105000 mi

US $300
Abnormal ticking. Inside valve train system. Undiagnosed. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

44640 mi

C $180
Service engine light, with hesitation an acceleration. 
76880 mi

C $389
Key stuck in ignition T.S.B. 
169880 mi

C $450
hesitates on accelleration 
89000 mi

US $500
coil on plug 
113000 mi

US $200
replace (1) oxygen sensor 
135000 mi

US $70
Leak from plastic portion of upper radiator hose. Replaced hose. Also replaced coolant as service was due soon. 
143000 mi

US $263
serpentine belt failed. replaced main serpentine belt, both idlers, and tensioner. 
86000 mi

US $70
Replaced serpentine belt. 
158300 mi

US $203
Felt as if you had taken your foot off of the throttle 
88000 mi

US $2700
ECU burned out, leaving all 6 coils open, melting each one. Had to replace ECU and all 6 coils. 
159000 mi Fuel pump, car died in the middle of nowhere, outside of cell reception. Idler pulley and serpentine belt. 
170000 mi Water pump. 
227000 mi Trip computer not working correctly. Resets at random. Car not worth cost of repair. 
235000 mi Water Pump failed. 
289500 mi

US $101
Heater hose T-junction cracked. Heater hoses/coolant replaced during repair as well. 
27900 mi Vibration or buzzing noise coming from the engine compartment or instrument. The symptom and repair was describe in TSB 07-17-5. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

19220 mi

C $480
electrical problem, would not start sulfur smelle 
42160 mi

C $500
Unintended acceleration. The dealer could find no problems. 
76240 mi muffler pipe welded back on; oil change 
2000 mi Terrible in-city gas mileage, 13 mpg 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

115000 mi

US $477
Replaced thermostat after obdII light issued code P028 (Engine fails to reach operating temperature in required time). 
55180 mi

C $340
Engine light came on. Thermostat was replaced. Issue resolved. It had been running cool. 
71000 mi

US $62
DTC for "engine warmup time exceeds threshold" set, temp gauge reads low. Replaced thermostat. 
129000 mi

US $60
Replaced cylinder cover gasket. Did plugs while i was at it. 
17360 mi Thermostat stopped working. 
29000 mi Idle 2500-3500 RPM after warm up. Shut off and restarted engine, same symptoms. Called dealer, no idea. Went back out, started car, now worked perfectly. Has not recurred in 3000 miles. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

31414 mi Fuel Cap Sensor light stuck on. Dealer replaced Cannister Vent Solenoid Assembly at no charge under bumper to bumper warranty. 
70000 mi

US $384
Serpentine belt and belt drive pulley were squeaking. Both items were replaced. Heat shield was making a rattling noise from under the car while traveling at highway speeds. There is a TSB from Ford on this issue. Heat shield was re-secured. 
6820 mi Motor mount. 
98000 mi

US $1200
Idler pulley bolt failure 
103000 mi

US $500
Second idler pulley bolt failure 
46000 mi

US $33
Heater was always producing cool air. Onboard computer reported P138 coolant under temperature code (i.e. check engine light came on and that was the code it reported). Replaced thermostat. 
52000 mi

US $15
Received code 491 about secondary air pump failing. Checked hoses for leaks but were fine. Replaced 50A relay to the secondary air pump and problem solved. 
59000 mi

US $50
Replaced downstream oxygen sensor after receiving code P420 Catalyst system efficiency below threshhold 
78000 mi

US $10
Code P0491 and P0410 secondary air injection system. Not enough air was flowing from secondary air pump; pump is working but air filter was really dirty. Replaced it and hoping for the best. 
132000 mi

US $50
Replaced belt tensioner. 
91000 mi

US $300
Received P0128 Code for Coolant Temperature Low. Took to shop and replaced Thermostat. Very common issue on 2.3L I4 Ford Fusions for this model year. 
2000 mi Car accelerated when foot off gas pedal. Able to stop, noticed two yellow wrenches, turned off car and appeared to reset. Garage could not replicate, had car for almost one week, put monitor in car for 2 weeks with no further probems, yet! 
47000 mi Clicking or squeal noise when start up. Noise gone after 15~30min. Detected problem 4 months ago. Dealer replaced a belt. Noise persisted. This week, dealer identified the tensioner was the problem. Replaced tensioner. Noise is gone. 
67000 mi

US $176
Engine would not reach proper operating temp. Replaced thermostat. 
30000 mi Check engine came on, later took car to dealer, they discovered that thermostat is bad. Replaced at N/C under extended warranty. 
108000 mi

US $624
Check engine light was on. Dealer diagnosed the problem as thermostat failure and MAP sensor. Replaced thermostat and cleaned MAP sensor. 
65000 mi

US $75
Thermostat 
58000 mi Replaced #3 coil pack. 
76700 mi

US $75
Failed thermostat 
84000 mi

US $250
Check engine light staying on. Analyst said the engine temp dropped after driving. Thermostat replacement seems to have cleared the error. 
93400 mi

C $600
accessory drive broken - replaced 
114000 mi

US $320
Thermostat had been stuck open for a few months. Also serpentine belt squeaking. Replaced thermostat, belt, and tensioner pulley. 
126000 mi

US $1000
Engine started knocking a couple months ago. Finally threw a rod. Replaced entire engine. 
136000 mi Blew second engine. Vehicle sitting until summer to replace it again. 
115700 mi

US $60
Cooling System--Replaced thermostat 
91000 mi

US $100
Replaced thermostat under Ford ESP warranty. 
US $22000 At 17,500 miles the check engine and wrench light came on. Dealer replaced throttle body, accelerator pedal sensor, and needed additional help from Ford Techline to return the car to normal operation. 
17000 mi PCM failed. Needed to be replaced along with throttle body and throttle pedal sensor. 
48000 mi Check engine light. P0128 code. Reset code. 
66000 mi

US $150
DTC Code P0128 - thermostat stuck open. Replaced t-stat 
62000 mi Shifting sensor malfunctioned 
184500 mi

US $850
Throttle control needed to be replaced. 
194300 mi

US $920
Oil pan needed replacing (wore out after 193K miles) 
200000 mi

US $633
Secondary air pump had to be replaced Secondary air injection pump diverter valve needed to be replaced. 
187000 mi

US $200
thermostat replaced 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

116560 mi

C $2600
Overheated ignition coils, required computer replacement as per TSB. 
97000 mi

US $230
Replace rear engine mount 
68780 mi

C $197
Key stuck in ignition. This dealer would not look at car. It was Friday, 3:30 pm. Their fix was to program a key so door would lock. Gave wife a deal. Instead of usual $65, charged only $50. Key stuck in ignition. Tech dismantled lock cylinder, made small adjustments and lubricated. Transmission shifter needed adjustments in various areas. Dealer re-programmed door key provided by previous dealer to be an ignition key. 
81860 mi

C $270
Front engine seal was replaced, along with serpentine drive belt 
34000 mi

US $175
Replaced throttle body. 
126500 mi

US $420
Tensioner locked up destroying belt 
135000 mi

US $105
Had to refresh the pcm due to hard start issue. 
18000 mi The Fusion had a computer reflash in early August. I didn't have any problems, but I read on forums that it improves shifting so I had it done. I didn't mind the shifting before, but it does seem to be smoother now. 
1000 mi Computer reflash for transmission shifting issues. 
80000 mi

US $1300
Timing belt had to be replaced at 80,000 miles. Engine lost basically all power and all engine oil burned up and almost lost the engine. The oil had just been changed 200 miles before this. Totally cost a little over $1300. Car is a POS 
132000 mi

US $800
One of the injectors misfired in the rear set and had to be replaced. 
158200 mi

US $79
Replace top pulley and main serpentine belt 
167000 mi

US $145
Alternator died, oil leaking on it from sensor seal on valve cover 
3100 mi Reflash PCM High idle speed at start up. No cost under warranty. 
5000 mi TSB for throttle response and transmission shifting issues. 
102300 mi

C $200
air sensor to the carb was not functioning and effected starting the car 
175000 mi

US $340
Ignition coils replaced. 
64000 mi

US $135
It was the thermostat. It failed to work. 
3000 mi re-torqued the top end. 
167000 mi

US $3000
Computer went out and caused 3 coils to go out. 
16000 mi A faulty transmission control module caused intermittent stalling and various drivability problems. 
28000 mi "Ticking" noise heard from engine within first 15 min. of driving or until engine reaches normal operating temp. 
29000 mi

US $180
I perceive the noise as being related to the lifters or perhaps some reciprocating part in the top end. The engine sounds as though it is slowly coming apart. Everyone who should take responsibility assures me that this is normal but it isn't. 
30000 mi ticking sound from engine after warmup was bothersome. The dealer did not find anything unusual. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

48000 mi At 48,000 miles, the engine develops a metal-on-metal "knock". One of the valves broke off the rod, severely damaging engine. Had to replace whole engine. Traded car in right after getting it back. 
99000 mi

US $500
thermostat stuck in on position 
143000 mi

US $2800
Catalytic converter 
135800 mi

US $5100
Piston rod bearing spun 
79000 mi Severe throttle lag, stumbling idle when cold, repeated Check Engine Light on for temperature not getting warm enough. Reflashed PCM for throttle concern to latest update. Concerns appear to be gone for the past few weeks. 
96000 mi

US $120
Thermostat. Vehicle has had on and off problems with running too cold. P0128. 
75000 mi

US $328
Thermostat stuck open. After diagnostic, problem confirmed. Thermostat and housing replaced. 
66500 mi

US $120
Though mostly functioning properly, the thermostat failed to bring coolant to correct temp level, causing check engine light to come on. Thermostat replaced, check engine light off. 
69000 mi

US $160
Accessory belt and belt tensioner replaced after tensioner began squealing regularly 
57300 mi

US $430
Replaced an engine sensor (and spark plug) due to a check engine light. 
50000 mi

US $1000
Bad plug coils 
58700 mi

US $200
cooling, thermostant out 
64000 mi

US $16
oil filter cover broke , replaced my self 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

74000 mi

US $400
check engine light on, an emissions valve was bad, expensive small part at $300 
97000 mi

US $400
Oxygen sensor. 
111000 mi Spring loaded idler pulley needed to be replaced. Replaced belt while at it. 
115940 mi

C $350
valve cover gasket replaced 
35000 mi Transmission "reflashed" due to "late shift" from 1st to 2nd gear upon startup when vehicle sat for more than 5 hours. 
63000 mi

US $4100
I experienced some rod knock, so a had a shop replace the engine with a rebuilt unit from S & J out of Spokane, WA. This engine comes with a non-prorated, 7yr/100k mile warranty! 
25000 mi Check engine light came on, problem was thermostat stuck open 
63500 mi

US $180
Leaking valve cover gasket replaced. 
39000 mi

US $285
Replaced canister vent valve assembly. 
101000 mi

US $500
Air pump valve replaced 
125500 mi

US $465
Key would not come out of ignition. Replaced cylinder and lock 
135000 mi

US $275
belt idle pulley became noisy. Replaced pulley and belt 
164000 mi

US $441
Replaced thermostat 
20000 mi Gas intake problem. 
55000 mi

US $250
Thermostat 
83000 mi

US $450
Thermostat change, oil change, tire rotation 
63000 mi

US $250
Check engine light indicated electronic thermostat was faulty. Replaced thermostat. Also changed front disc brake pads. 
130000 mi MAF code, check engine light 
172000 mi

US $500
Replaced thermostat to clear P0128 Code. 
197000 mi

US $3500
o2 sensors 
100000 mi

US $400
Fuel was leaking into Three of four spark plug holes. The valve head was replaced and spark plugs replaced. The spark plugs were due for replacement. Oil was not supposed to be there in the spark plug holes (Where the spark plugs reside). 
54000 mi

US $415
Check engine light= thermostat failure. Also completed oil change/tire rotation and recently a trans fluid change (unsure why it was so dirty so early). 
67000 mi

US $260
Ignition coil on #2 cylinder failed. Start the car, it runs briefly ok then starts to spit/cough/sputter, then sort of catches itself and the check engine light comes on.  Ignition coil failure #4 cylinder; second IC failure in less than a month; very displeased!! 
91000 mi

US $235
belt tension er 

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See TrueDelta's information for all Ford models.

Ford Fusion Engine 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.