2006 Ford Fusion Engine Problems

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2006 Ford Fusion repairs by problem area

Engine (26%)

Transmission and Drivetrain (10%)

Brakes and Traction Control (10%)

Suspension and Steering (9%)

Electrical and Air Conditioning (17%)

Paint, Rust, Leaks, Rattles, and Trim (19%)

Other (9%)

Chart based on 229 repairs.

2006 Ford Fusion engine repair cost distribution

$2500+ (13%)

$1000 - $2499 (6%)

$500 - $999 (13%)

$100 - $499 (62%)

< $100 (6%)

Chart based on 47 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
Non-members can see only ten 2006 Ford Fusion repair histories. Log in or join us to see them all.

2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

5000 mi TSB for throttle response and transmission shifting issues. 
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. 
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. 

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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. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

35000 mi Transmission "reflashed" due to "late shift" from 1st to 2nd gear upon startup when vehicle sat for more than 5 hours. 
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. 
83000 mi

US $450
Thermostat change, oil change, tire rotation 
25000 mi Check engine light came on, problem was thermostat stuck open 
63500 mi

US $180
Leaking valve cover gasket replaced. 
20000 mi Gas intake problem. 
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 

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2006 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 2006 Ford Fusion problems occur, check out our car reliability stats.