Ford Fusion Ford Fusion

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Expensive Ford Fusion repairs by problem area

Engine (29%)

Transmission and Drivetrain (20%)

Brakes and Traction Control (15%)

Suspension and Steering (23%)

Electrical and Air Conditioning (11%)

Paint, Rust, Leaks, Rattles, and Trim (2%)

Other (0%)

Chart based on 105 repairs.
See TSBs and recalls for the Ford Fusion.

Ford Fusion repair cost distribution

$2500+ (21%)

$1000 - $2499 (79%)

$500 - $999 (0%)

$100 - $499 (0%)

< $100 (0%)

Worried about potential repair costs? An extended warranty can provide peace of mind.

Chart based on 67 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2017 Ford Fusion 4dr Sedan

turbocharged 181hp 1.5L I4 6-speed shiftable automatic FWD

71000 mi

US $1900
Car wouldn't start, brought in on May 5, battery replaced, picked up May 24 (we were on vacation in between), car wouldn't start AGAIN, car brought in again on May 25 and picked up June 10, APIM was bad and had to be replaced. 

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2015 Ford Fusion 4dr Sedan

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

150015 mi

US $1200
lost rear break function. Break caliper replaced electric parking break replaced break fluid replaced. 

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2014 Ford Fusion 4dr Sedan

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

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. 

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2013 Ford Fusion 4dr Sedan

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

6780 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. 
24480 mi

C $100
Windshield cracked with no sign of stone chip or bruise. Dealer would not do anything as they said they had a one year warranty on glass, as they had replaced windshield when I bought the car as it had stone bruise caused by dealership. 
54994 mi

C $1500
Fog light broken by rock, shop replaced light 
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. 

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2013 Ford Fusion 4dr Sedan

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

45000 mi

US $175
Replaced rear brake pads and rotors. 
79000 mi

US $2000
Water pump failure. Also received new Water Pump, spark plugs, coolant, timing belt. 
125000 mi

US $4000
The whole transmission had to be replaced at a cost of $4000. This apparently is a very common problem with these cars but Ford refuses to issue any kind of recall or warning to have the system checked, flushed, and refilled. 

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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. 
80000 mi

US $100
Water Pump Failure 
91349 mi

US $250
Sway bar loose. 
159719 mi

US $350
Car was sputtering upon acceleration. Tune up was performed and spark plugs and wires were replaced. 
165000 mi

US $1300
Thermostat replaced Valve cover gaskets replaced - oil leak Timing Belt replaced 

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2013 Ford Fusion 4dr Sedan

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

50000 mi

US $152
Replace 12V battery 
60000 mi

US $170
Reprogram AC module and touchscreen display to make AC & heat functional again 
75485 mi

US $400
Had to replace engine mount, CV axle  and repair transmission leak Troubleshoot and fix wiring. Reset engine light 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

100000 mi

US $1400
Rear rotors worn beyond spec, rear pas worn out, left side tires worn to belts on inside Small battery located in truck was 8 years old and needed replacment 

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2012 Ford Fusion 4dr Sedan

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

75000 mi

US $2200
AWD PTU was whining and smelling horribly. PTU needed to be replaced as it is a non-servicble part. 

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2012 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

127720 mi

C $1500
Replace brake pads and rotors 

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2012 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

29000 mi

US $2155
Replaced electronic assist power steering module 
58000 mi

US $325
Front inside door handles won't retrack fully. Mechanism prevented locking of doors. 
126000 mi

US $150
Sound in front of car when stopping or take off from stop 

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2011 Ford Fusion 4dr Sedan

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

66000 mi

US $2800
All Wheel drive Power Transfer Unit leaking gear lube. Smell is noticable in winter with windows shut. Unit is only on AWD models of Edge, 500, and Fusion. Pricey little hunk of steel: 850+tax USD. Install is 8 hours, another $1200 bucks. But that's what a stimulus check is for I suppose. I was going around big bad Jeeps with that little Ford come the first big snow ! 
72000 mi

US $250
Replace all 4 OEM rotors and pads and shims with Raybestos parts 

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2011 Ford Fusion 4dr Sedan

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

74000 mi

US $1900
Electric rack and pinion system died. Replaced power steering assembly. 
74000 mi

US $365
Control arms make constant noisy creaking sound. Dealership said nothing wrong with the car; that it was caused by the control arm bushing drying out. They said they could "fix" it for $1700 in control arms, or they could try lubing it. 
80000 mi

US $1500
Issue with air conditioning, believe it was the.blower motor and module 
133000 mi

US $1000
passenger right rear caliper was frozen, caused premature wear of brake pads. RF lower control boot was split and also had excessive play. Both control arms were replaced 
175000 mi

US $800
calipers were sticking and pulling car to the right. Brakes, rotors, and calipers replaced. 

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2011 Ford Fusion 4dr Sedan

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

47120 mi

C $383
Noise form driver side, replaced one arm. Joint ball of passenger side suspension torn, replaced. 
104160 mi

C $5300
Car had no transmission in the middle of a trip. towed to dealer, Got checked and found transmission failed. Replaced with an used transmission. Never buy a ford again. 

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2011 Ford Fusion 4dr Sedan

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

95000 mi

US $1579
passenger front hub assembly required repair 
95200 mi

US $1150
ECM required replacement due to complete failure 
99000 mi

US $735
A/C compressor failed resulting in complete replacement of unit as well as flushing of complete system and evac/recharge 
101000 mi

US $118
Drivers interior door handle inoperable. Replaced interior door handle assembly 
105000 mi

US $194
left front headlamp assembly required replacement due to a faulty socket 
106000 mi

US $675
Noise and inability to do an alignment due to excessive wear. 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

107260 mi

C $1800
New suspension on all 4 wheels. new tie rod. 
90700 mi

US $400
Battery cable was corroded and entire harness had to be replaced. Unable to just replace the positive battery cable. 
96900 mi

US $350
The valve body cover was leaking. Fluid drained, cover removed and resealed. Had transmission flushed but didn't include that in the repair cost. 
130000 mi

US $1500
Flex plate cracked causing a loud knocking sound. The flex plate was replaced. 
78000 mi

US $200
Replaced faulty fuel filler neck 
92100 mi

US $1500
Cracked and leaking transmission cooler lines replaced Faulty ignition wiring harness causing two cylinders to misfire, including an injector completely failing due to bad wires. Bad accessory belt tensioner needed replacement. 
105000 mi

US $1500
Left and right control arm bushings worn. Replaced both control arms. Replaced front brake pads 

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2010 Ford Fusion

Engine not specified

93000 mi

US $1100
Out of Town: Brakes spongy suddenly with no warning. Dash lit up like Christmas tree. Brakes pushed to the floor and slowed to a gradual stop. In residential area, 20 mph. Can't imagine if on the hwy. Intermittent issue. Solenoid and brake replaced. in a residential area (THANK GOD) the brakes gave out AGAIN, Identical issues, Identical light show on my dash. Apparently as the solenoid and brake booster went out, they were wearing out the ABS module. Now the ABS module went kaput. 

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2010 Ford Fusion 4dr Sedan

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

30000 mi

US $100
Drive side interior door handle broke. Replaced. (Seems to be a common problem). 
56200 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. 
56300 mi

US $168
Driver's door handle failed (2nd time). These are very cheaply made and apparently fail often. 
61000 mi

US $1080
Leak in steering/AC condenser - unit replaced 
88600 mi

US $1000
Rear caliper guide pins had corroded causing the pads not to release and drag against the rotor causing extreme premature wear. Had to replace rotors and pads again. 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 
90000 mi

US $850
Vibration, worn transmission mount, replaced Tire sensor failed and replaced 
98000 mi

US $1600
Vibration worsening with time. 3rd trip to dealer to diagnose. Replaced all 3 motor mounts. Runs like new. 
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. 
122000 mi

US $400
AC blows intermittent , shuts down, then blows again for 15sec to 2min. Replace AC temp sensor . Replace motor mounts, second time in 3years 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

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%. 
30000 mi

US $156
Noted a smell of burning brakes while driving. Rear-left caliper was locked. Took to mechanic, found both rear pads shot-replaced both. Nothing wrong could be found with the calipers; suspect the parking brake froze during cold weather. 
41000 mi

US $3100
Took car for oil change; shop noted tranny fluid leak and no fluid. Went to AAMCO; fluid gone, needed new gears,torque cvtr,axle,bushing and half case: $3100. Known problem:TSB-14-005. Vehicle 3 mo out of warranty. Ford: "Too bad for you." 
62000 mi

US $1400
A/C sensor failed again. Cheap part, lots of labor to replace. Passenger-side coil spring failed while vehicle was parked, a few minutes after I drove it home. Mechanic replaced the coil spring and both front struts. This would have been very,very bad had it been 10 minutes earlier. 
64000 mi

US $947
Replaced both tie-rod ends, + front discs and pads. 
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. 
100000 mi

US $2000
Brake bads replaced and caliper needed to be replaced, had to wait for them to get one. 
37000 mi

US $210
Engine check light. Dealer said error was for transmission and firmware update fixed it. 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. Engine check light. Vapor valve was found defective 
68000 mi

US $1000
Driver's seat replacement due to a heating element failure 
68820 mi

C $280
Pulleys for drive belts were humming. Upper and lower tensioner pulleys replaced. 
70560 mi

C $160
Driver window would not go down. Cable for pulley system broke. Cable was replaced. 
95960 mi

C $275
Transmission lines were rusted and leaking in 2 location. New transmission lines installed. 
98860 mi

C $300
Front brakes rotors and seized calipers. 
99820 mi

C $2234
Lost power assist steering. 'Advance Trac' and 'Service Power Steering Now' lights on. Dealer replaced both rear TPS sensors in tires!! Power steering restored. Power assist steering went out again, 22 days since the same trouble was repaired. This time they say the rack and pinion is gone and needs replacing. Very expensive repair and known trouble by Ford but they refuse to accept responsibility. 
104740 mi

C $250
Tension pulleys making noise. Needed to be replaced. 
105400 mi

C $500
Both wheel bearings replaced Replaced front and back pads and rotors. Freed stuck calibers. 
120500 mi

C $300
Both sides have tie rods with excessive play in them. 
109200 mi

US $200
EVAP solenoid was bad 
92000 mi

US $600
Brought in with harsh shifting after adding 1.5 quarts of fluid. They couldn't find a leak and advised that the fluid was badly burnt. They also changed other fluids during this visit 
100400 mi

US $400
Transmission leak found. Replaced drivers axle seal 
139000 mi

US $1100
Front spring cracked. Replaced both springs and struts Exhaust flex pipe rusted out. 
154000 mi

US $750
Fuel smell in cabin while idling. Dealer found a spark plug loose. Also replaced valve cover, and a solenoid. 
188000 mi

US $500
Transmission cooler lines were leaking 
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. 
120300 mi

US $100
Upper motor mount replaced. 
122000 mi

US $1200
Dash was pulled to replace defective air conditioner sensor $800.00 Rear brake pad was hung up causing wear. Declined this repair because i only want my own mechanic to do brake work. THESE SMALL PADS are a ripoff. Thanks Ford. My mech had to use special tools to remove the frozen damaged lug nuts that Bevis/But-head did to my car. Dealership said damage was due to old age of lug nuts.!!!!!!!!!!!!! Talked to customer service rep in Detroit. Would have most likely had to be towed at great expense had i found out about this on the road. 
123000 mi

US $120
LUCAS TRANS-FIX Worked -----Lower motor mount replaced. Still had loud noise when shifting at high speed and found that it was due to 6F35 transmission. Lucas transmission fix was added and after 3 weeks the noise was gone. 
130000 mi

US $200
Tire pressure sensors replaced. Ordered VDO sensors from Rock Auto and had my mech install. 
45880 mi

C $160
Serpentine belt was worn and needed replacing. Replaced by backyard mechanic using an AC Delco belt 
57660 mi

C $200
Cracked spring on left front. Replaced whole strut/spring assembly for ease of repair and cost. 
64480 mi

C $100
Car was not shifting properly. Getting stuck in 1st, 2nd. Trans fluid was black and slightly low. Trans fluid replacement fixed issue. 
68200 mi

C $1250
Electric steering rack failed, needed replacement. 

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2010 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

150000 mi

US $1500
CV joint Engine mounts 
214000 mi

US $1400
Front Calipers 
90000 mi

US $300
tie rod replacement 
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. 
117000 mi

US $1100
Tie rod loose 
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
Left front wheel hub bolt was loose, causing noise when front wheels were turned. This could of been a series problem if I (owner) did not notice the noise and take it in for inspection and repair. 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. 
87000 mi

US $1400
car started making noise about 2 months after last repair. Both front wheel bearings needed to be replaced. I suspect dealer may have botched initial repair job. 
112000 mi

US $1000
Noise from front end in sync with road speed. Wheel bearings replaced. 

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2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

97000 mi

US $1800
Car was leaking gear oil. A gear inside the differential (located inside the transaxle) was coming apart and metal shavings were very thick on the drain plug. The dealer ordered and replaced the differential with a re-manufactured one. 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

55860 mi

C $100
Weak battery under stress. Replaced to avoid problem in the winter. 
83700 mi

C $500
Replace 2 front wheel bearings 
143220 mi

C $1500
Replace intake gasket to stop oil leak. replace one catalytic convertor and front end of exhaust 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

119660 mi

C $1675
Broken engine mount 
55000 mi

US $150
Interior door latch for driver's door broke. Door could not be opened from the inside. 
59600 mi

US $2100
Moon roof track was broken and motor contained plastic shards from the track. 
48360 mi

C $1290
Repair oil leak from oil pan and engine output seal 
84320 mi

C $200
Replaced coolant manifold and temperature sensor due to leak at coolant temperature sensor. 
81500 mi

US $2000
Engine control computer replaced 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

85000 mi

US $2100
PCM failed and damaged the ignition coils and plugs requiring replacemet of all items. 
105000 mi

US $150
Wheel bearings went bad on the front end. Both were replaced. 
96100 mi

C $2000
Transfer case or Power Transfer unit, does not have a drain plug, this is not considered a serviceable part. The only way this can be changed is to remove the part and turn it upside down at 5.5hrs mechanic labour. OEM 1600-2000, wrecker $500 Driveshaft, bad ujoint, again ujoints are not replaceable and you have to buy another driveshaft. OEM 1600, aftermarket 800 Do not buy a ford AWD in the 130km and up range, you are asking for this repair! I know this is my last ford! 
45260 mi

C $218
Car began showing symptoms of hard/long cranking (also SRS light would not go out after car started) 
85560 mi

C $1700
Noise and vibration when driving from right side of car. Dealership diagnosed as two bad right side wheel bearings (front/rear) both replaced and car returned to normal operation 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

71000 mi

US $3000
Lemon car all the way around. Had been noticing problems with the transmission when first bought car and under warranty. 2,000mi out of warr and transmission blew. Ford would not honor their part. We paid...they don't care. Will never buy Ford again. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

54000 mi

US $604
All new brake pads & rotors, balky (sticking) LR caliper freed up. Even 3,000 miles later, car stops like brand new. Gas mileage went up 2 mpg city with LR caliper fixed. Corroded spot fixed on a wheel lip causing a tire leak at the bead. 
46300 mi

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

US $461
Left-rear brake caliper had seized, causing those pads to drag & make the whole assembly hot. A garage had freed it up in Spring 2014 but it obviously only lasted a year-and-a-half. A local Ford dealer replaced the caliper this time. 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. 
80000 mi

US $697
Engine light came on, I checked it & it read PO128 : a bad cooling thermostat. Car had been running cool so it was obviously stuck open. Garage changed it for $199.56 Front end squeak while turning at low speeds. Garage said tie-rod ends were bad & could be the problem, but said it''s usually ball joints even though mine were in good shape. Tie-rod ends replaced at $148.04 *note* ...The front end squeak never went away and I suspected my ball joints were very dry inside. In March I bought and used a grease needle. A ten-minute job and the car's front end is very quiet now :) 
82083 mi

US $694
Replaced all brake rotors and pads plus two calipers 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. 
88500 mi

US $264
Had a fluid drip - not engine coolant - under the radiator. A local repair shop found the transmission lines going to the cooler built into the radiator were leaking and replaced them. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

88000 mi

US $2700
ECU burned out, leaving all 6 coils open, melting each one. Had to replace ECU and all 6 coils. 
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 (1) oxygen sensor replace sensor in dashboard that was preventing the AC compressor from running replace leaking transmission cooler lines that run to the radiator, Slow leak. Showed a red spot under that car when parked overnight. 
118000 mi

US $1000
Replace both tie rod ends. Steering wonky. replace sway bar links - front. Making noise Replace both rear calipers. Brakes were repaired recently but calipers were problematic and should have been done earlier. 
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. 
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. 
110000 mi

US $175
Door lock front right door was not locking replace interior mechanism and handle and lock. 
115000 mi

US $140
Brake Switch Transmission would not shift 
122000 mi

US $145
Low oil pressure light came on Oil leak was fixed. 
128000 mi

US $625
Right Rear Sway Bar and Right Front Tie Rod also had some door dent bumped out and rear seat work done patch job 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

64480 mi

C $1400
This car has been a disaster since the day i got. shaft in transfer case replaced, both front half axle shafts, balljoint, hanger bearings x 2, and 1 front wheel bearing. This is a car I have only owned since dec of 2008 not impressed ford 
93620 mi

C $3900
there is a steel shaft that transfers torque with fords AWD system. this part has now been replaced # times approx every 50000km 
18600 mi

C $200
car 2x would not start 
19220 mi

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

C $500
Unintended acceleration. The dealer could find no problems. Electrical -running lights wouldn't turn off, locks wouldn't work. 
47120 mi

C $1600
Replace wheel bearings front and rear. 
100500 mi

US $600
Light noise while car was in motion got much louder - carrier bearing on rear driveshaft had failed due to an imbalanced driveshaft (TSB issued but wasn't fixed by prev. owner). Repair was to replace entire driveshaft assembly. 
118500 mi

US $230
Squeaking and uneven tire wear caused by worn out struts. Replaced front struts and rear shocks. 
140000 mi

US $1100
Failed transfer case was causing loud grinding noise. Needed replacement. 
166000 mi

US $200
Right front wheel bearing 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

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 $120
Engine started knocking a couple months ago. Finally threw a rod. Replaced entire engine. CV boots have been cracked for about 30k miles. Finally replaced them. They were NOT making any noise. 
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. 
66000 mi

US $150
DTC Code P0128 - thermostat stuck open. Replaced t-stat 
98000 mi

US $1200
Idler pulley bolt failure Tie rods replaced 
103000 mi

US $500
Second idler pulley bolt failure Axle boot shredded by serpentine belt during previous idler pulley failure. Axle replaced. 
136000 mi

US $1000
An intake manifold runner control had to be replaced. A servo motor burned out. Both front axles were replaced to address vibration under acceleration Warped rotors. Brake rotors replaced. 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

90000 mi

US $100
changed side curtain airbag a second time.  
166400 mi

US $3000
Computer went out and caused 3 coils to go out. 
66000 mi

US $1300
Compressor needed to be replaced. 
116560 mi

C $2600
Overheated ignition coils, required computer replacement as per TSB. 
95800 mi

US $1100
Replace tires, struts and shocks 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

92480 mi

C $1000
Front struts worn out 
94240 mi

C $200
Intake gasket 
95480 mi

C $1000
Pads, rotors, calipers, front and rear 
104000 mi

US $1300
Clutch went out. Throwout bearing failed. Starter. 
90000 mi

US $1750
complete rebuild of transmission assembly and casing complete rebuild of transmission assembly and casing 
99000 mi

US $500
thermostat stuck in on position front passenger side CV boot torn causing metal rub and major squeak... had to replace whole axle because you can't buy just the boot 
142000 mi

US $2800
Catalytic converter 
50000 mi

US $1000
Bad plug coils 
128000 mi

US $5100
Piston rod bearing spun 
167000 mi

US $680
Brake reservoir. Didn't fix problem now dealer wants 1100.00 to replace abs valve. 

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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. Valve assembly. 
187000 mi

US $1000
Replaced the original front CV shafts  as well as rear wheel bears. Also front right wheel bearing. 
172000 mi

US $500
Replaced thermostat to clear P0128 Code. Replaced front struts due to noises. Still may have to replace tie rod ends. 
197000 mi

US $3500
Replaced, struts (4), front rotors and pads. A arms lower control arms (4), stabilizer links, tires o2 sensors 
217700 mi

US $100
Battery 
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). 
110000 mi

US $1800
CV boot  control arms replacement 
141000 mi

US $400
Right axle, which had been replaced in February 2014, had another failure. 
39000 mi

US $285
Replaced canister vent valve assembly. 
98000 mi

US $360
wheel hub worn 
101000 mi

US $500
Air pump valve replaced 
126300 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 
139000 mi

US $370
lower control arm (front right) replaced 
160300 mi

US $500
replaced left and right front cv axle shafts. Both had torn boots 
162000 mi

US $917
replaced front struts, worn Replaced driver seat track (power seat) 
163400 mi

US $441
Replaced thermostat 
166000 mi

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

US $370
replace alternator 
215400 mi

US $1000
replace 4 brake rotors, calipers, pads, hoses 
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! 
70000 mi

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

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Ford Fusion Expensive Problems

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