2006 Ford Fusion Ford Fusion 2006

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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 (20%)

Other (9%)

Chart based on 242 repairs.

2006 Ford Fusion repair cost distribution

$2500+ (6%)

$1000 - $2499 (8%)

$500 - $999 (17%)

$100 - $499 (52%)

< $100 (17%)

Chart based on 100 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

Engine not specified

Ford Fusion in Mississippi, United States
Jul 2007 - Mar 2010
Aug 2007

10000 mi
Driver interior door handle was starting to "bubble" in appearance. Dealer ordered new handle and will call when handle arrives. 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

Ford Fusion in Ontario, Canada
Jan 2012 - Sep 2013
Mar 2012

102300 mi

C $200
air sensor to the carb was not functioning and effected starting the car 
Jun 2012

109740 mi

C $500
replace moonroof motor to open and close. Checked fuses and contact switch for functioning and both were not the problem. 
Jul 2012

112240 mi

C $50
Dealer opinion on why the moonroof motor was not working. Need to replace moonroof motor that is hidden between the inside ceiling of the roof and the outside metal roof. Major job that requires the whole inside ceiling to be removed. 
Oct 2012

119660 mi

C $250
remove complete inside roof to interior to get at the moonroof motor to just close the moonroof from a vent position to complete closure. Did not replace the motor as the cost for this was not acceptable from the dealers. 
Dec 2012

123380 mi

C $350
struts replaced. 
Jul 2013

135160 mi

C $350
remove motor to sun roof and close sunroof permanently. 
Ford Fusion in Ohio, United States
May 2012 - Sep 2015
Sep 2012

97000 mi
Gasket came off of sunroof glass due to rust in the gasket spine. Ford offers no spare part -- the entire glass must be replaced. 
Dec 2012

98000 mi

US $135
replaced rear pads and rotors 
Feb 2013

102000 mi

US $60
Driver's door handle broke and trapped me inside. From the internet, this is a common problem with a badly designed handle mechanism. I bought a new handle from the dealer and installed it in an hour. Door inside is beautifully engineere 
Nov 2014

134000 mi

US $400
Trans cooler lines rusted through and were leaking Rear pads worn out on one side only (again). New rotors + the two pads fron the last time. 
Sep 2015

137000 mi

US $250
Window regulator fail 
Ford Fusion in Mississippi, United States
Sep 2006 - Sep 2013
Jul 2006

3000 mi
re-torqued the top end. 
Feb 2007

12000 mi
changed a swith in the AC 
Jun 2007

20000 mi
Changed side curtain air bag because it was seperating from the seat. 
Sep 2008

48982 mi
Changed the gear shifter after the key became stuck in the ignition. 
Dec 2009

90000 mi

US $100
changed side curtain airbag a second time.  
May 2013

167000 mi

US $3000
Computer went out and caused 3 coils to go out. 
Ford Fusion in Ontario, Canada
Jun 2011 - Oct 2015
Jul 2011

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. 
Jun 2012

79980 mi

C $150
Spring in FL door lock mechanism broke, cracking inside door handle and dislodging entire assembly. Door would open/close, but not lock. 
Nov 2012

86420 mi
Power steering fluid low with no obvious sign of leak. Fluid topped up and will be re-checked at the next interval, including dye injection if levels are low again. 
Apr 2013

91960 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. 
Jun 2014

104160 mi

C $300
Transmission lines replaced (leaking fluid). 
Jan 2015

107240 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. 
Ford Fusion in Vermont, United States
Jun 2011 - May 2014
Jan 2014

145700 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. 
Ford Fusion in New York, United States
May 2006 - Jun 2015
May 2011

75500 mi

US $500
Rear brakes and rotors were replaced. 
Jul 2014

123000 mi

US $40
license plate light fixture, state inspection item. 
Ford Fusion in Texas, United States
Aug 2009 - Mar 2016
Dec 2009

44000 mi

US $100
buzzing noise coming from behind the steering column. 
Jan 2011

53000 mi

US $70
rubbing/bumping sound in front, right of car near tire Busted button and mechanism on front dash compartment. Too costly to fix. Will live with it. Am not happy with the quality of the Fusion plastic interior (dash, door, etc). I expect better...especially for the price paid. 
Jun 2011

55000 mi
The inside driver's door handle broke. I cannot open the door from the inside; I roll down the window and open it from the outside. I decided not to repair the door handle because of the cost. 
Apr 2012

64000 mi

US $100
Car was having problems with acceleration and at times would jump sporadically while changing gears. The transmission had to be completely replaced. 
Mar 2014

82000 mi
suggested replacement of bar. repair too expensive, so I decided against the repair 
Mar 2015

97000 mi

US $230
Replace rear engine mount 
Sep 2015

103000 mi
suspension creaking. mechanic idicates the control arm may need to be replaced 
Ford Fusion in New York, United States
Aug 2007 - Jan 2012
Dec 2009

33000 mi

US $107
Took it to Shepard Ford as front left bearing needed replacing. They told me it was the brakes that needed repairing. I said it was not. Upon them furthing inspecting the car, they saw I was right. It was NOT the brakes!!!!! 
Sep 2010

42000 mi

US $1
I had to have the brakes replaced. Not under the extended warranty. 
Jul 2011

60000 mi

US $600
The front brakes needed to be replaced. Took the car in and they replaced them. 
Dec 2011

64000 mi

US $135
It was the thermostat. It failed to work. 
Ford Fusion in Ontario, Canada
Dec 2009 - Mar 2016
May 2010

16120 mi

C $45
"low brake fluid" warning message. Dealer said no code present. Took it in when light finally went on near dealer store. Dealer said master cylinder sensor bad. (ya think?) On repair invoice described part as brake switch. Paid labour only. 
Jul 2011

25800 mi

C $98
Inside driver's door handle stuck out after use. Remote would not lock door. Automatic locking after car starts moving would not lock door. Shop ordered new part from Ford, removed and replaced part. 
Oct 2013

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. 
Jul 2015

88640 mi

C $720
Went in for oil change. Had a squeak in front wheel. Was sensor for air pressure sensor. Replaced both tie rod ends. Replaced right side upper ball joint. 
Ford Fusion in Saskatchewan, Canada
Sep 2009 - Nov 2014
Nov 2010

81860 mi

C $445
Front engine seal was replaced, along with serpentine drive belt Remote start control module replaced 
Dec 2011

106640 mi

C $750
Tie Rod end was worn, replaced and wheel alignment done by dealer. I purchased new brake pads and rotors from dealer, then installed them myself as well 
Ford Fusion in Massachusetts, United States
Mar 2011 - Jan 2012
May 2011

109000 mi

US $195
technician found and replaced worn sway bar links. preventative maintenance, 100k service replaced spark plugs, flushed coolant system and transmission.  
Jun 2011

112000 mi

US $270
replaced worn out front brake pads and rotors 
Aug 2011

115300 mi

US $50
drivers door inner handle snapped causing the door not to lock and unable to exit the vehicle with the window closed 
Jan 2012

124000 mi
front turn signals went out and one marker stayed lit shorted to power the smart junction block needed replacement at $1,100 
Ford Fusion in Saskatchewan, Canada
Jan 2007 - Apr 2015
Mar 2014

116560 mi

C $2600
Overheated ignition coils, required computer replacement as per TSB. 
Ford Fusion in California, United States
Apr 2015 - Jul 2015
Jul 2015

92000 mi

US $1100
Replace tires, struts and shocks 
Ford Fusion in New York, United States
- Aug 2007
Aug 2007

9000 mi
Noise from driver side door. 
Ford Fusion in Ohio, United States
Jul 2008 - Jun 2011
Oct 2008

47350 mi

US $5
Right rear turn signal went out. Replaced both rear signals. 
Ford Fusion in Connecticut, United States
Jan 2006 - Mar 2016
Sep 2006

1000 mi
Computer reflash for transmission shifting issues. 
Jun 2008

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. 
Ford Fusion in North Carolina, United States
Mar 2008 - Apr 2011
May 2008

34000 mi

US $175
Replaced throttle body. 
Ford Fusion in Kansas, United States
Apr 2015 - Apr 2015
Jan 2015

80000 mi

US $1800
Air bag top end cover on dash of passenger side has come loose. Looks really cheap, broken and not attractive to look at. Cheap plastic and parts. Plastic is great for cars but American auto's use cheap built plastic compared to other makers Had to replace all chrome/plastic inside car as all door handles and fake chrome plastic pieces started to peel off. POS like all American vehicles. 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. Had to replace the driver door handle as it broke and would not lock leaving the doors unable to lock. Door handle stays in the open. American car companies look and feel cheap no matter what American car you buy including trucks and suvs. 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 
Ford Fusion in Tamaulipas, Mexico
- Sep 2007
Mar 2007

1860 mi
Driver seat Lumbar control cover by Warranty 
Aug 2007

8060 mi

$5
Back left turn bulb 
Sep 2007

8370 mi
Automatic Climate Control sensor and A/C blower motor relay cover by warranty 
Ford Fusion in Wisconsin, United States
Dec 2006 - Mar 2010
Sep 2006

300 mi
CD player died, it wouldnt take any CD's so had it replaced. 
Ford Fusion in Alabama, United States
Jun 2009 - Mar 2010
Aug 2009

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. 
Ford Fusion in Illinois, United States
Feb 2009 - Nov 2015
Nov 2014

175000 mi

US $340
Ignition coils replaced. 
Ford Fusion in Ohio, United States
Dec 2014 - Dec 2015
Dec 2015

122000 mi

US $20
front door handle broken. Got a part and fixed less than one hour Tie Rod end (both) boot torn. Replaced. 
Ford Fusion in Puerto Rico
- Dec 2006
Dec 2006

1000 mi
Took the car to the dealership for two TSB's: Front door rattle (passenger side) and front end clunk (suspension noise in right front side). No other problems until now. 
Ford Fusion in New Jersey, United States
Jan 2015 - Mar 2016
Apr 2015

126500 mi

US $420
Tensioner locked up destroying belt 
May 2015

127000 mi

US $750
Rust hole is rocker panel 
Aug 2015

128700 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. 
Dec 2015

135000 mi

US $105
Had to refresh the pcm due to hard start issue. 
Ford Fusion in District of Columbia, United States
Nov 2010 - Jan 2015
Dec 2010

81000 mi

US $80
Power Steering fluid leaking from the pressure sensor. Replacement entailed removal of the fender well liner, passenger front tire, and replacement part cost $42 from Ford dealership and 1 hr labor. 
Feb 2012

97700 mi

US $560
Both front hubs replaced, passenger hub mount also replaced as hub was seize-rusted on. Also replaced oil pressure switch. 
Aug 2013

132000 mi

US $800
One of the injectors misfired in the rear set and had to be replaced. 
Mar 2014

142000 mi

US $300
rack and pinion replaced with used oem 
Jan 2015

156000 mi

US $79
Replace top pulley and main serpentine belt 
Ford Fusion in Tennessee, United States
May 2006 - Apr 2008
Dec 2006

27000 mi
Still Waiting on Dealer to Fix Broken Lumbar Support in Drivers seat. 2nd Visit, still no satisfactory results. Still Waiting on Dealer to Fix Ignition switch that thinks the key is always in it. 2nd Visit, still no satisfactory results. 
Jul 2007

33000 mi
Fixed ignition switch. 
Oct 2007

34000 mi
Lumbar support fixed 
Ford Fusion in Oregon, United States
May 2006 - Dec 2011
Apr 2007

15000 mi
Had TSB 07-05-10 for wind noise at the B pillar performed. 
May 2007

15000 mi
Started to notice wind noise inside vehicle. I then did research and found the TSB for the B pillar wind noise. Noticed the wind noise was around this area. Took the vehicle to the dealership and they agreed. Part was ordered and arrived in about 2 we 
Ford Fusion in Oregon, United States
Jan 2007 - Mar 2010
Mar 2007

12000 mi
Air leak in drivers window; door rattle; dash rattle 
Sep 2007

17000 mi
Front rotors needed turning, front calipers needed adjusting. 
May 2008

30000 mi
Front brake rotors needed turning again. 
Ford Fusion in Alabama, United States
Dec 2006 - Mar 2010
Jan 2007

11000 mi
Had to replace the left rear turn signal bulb. 
Jun 2007

15000 mi
Door rattle. Rusted panel above license plate. Worn floor mats. 
Ford Fusion in New York, United States
Apr 2008 - Sep 2011
May 2008

16000 mi
A faulty transmission control module caused intermittent stalling and various drivability problems. 
Mar 2009

25000 mi
A "buzzing" noise was heard from the firewall area of the car that usually occurred within 15-20 min. after starting. The noise was most prominent at idle and low speeds but generally abated at speeds>40 mph.  
Jul 2009

28000 mi
"Ticking" noise heard from engine within first 15 min. of driving or until engine reaches normal operating temp. 
Aug 2009

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. 
Sep 2009

30000 mi
ticking sound from engine after warmup was bothersome. The dealer did not find anything unusual. 
Aug 2010

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. 
Ford Fusion in Ontario, Canada
Jan 2008 - Jun 2011
Feb 2008

35340 mi

C $180
Transmission shift between 1 and 2, in traffic was slipping or grabbing. New flash update and changed fluid (just to be sure). 
Ford Fusion in Arizona, United States
Apr 2008 - Apr 2010
May 2008

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. 
Aug 2009

46000 mi

US $40
Driver's inside door handle broke. Replaced the door handle mechanism. 
Ford Fusion in Iowa, United States
May 2006 - Sep 2012
Aug 2008

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. 
Ford Fusion in Michigan, United States
Jan 2007 - Mar 2010
Jul 2007

24000 mi
Passenger seat squeaks loudly when occupied. Dealership has not been able to resolve after 4 trips. 
Aug 2007

26000 mi
This was a continuation of the seat squeak problem noted previously. This time, a new seat track was installed but the squeak remains and now I have a new rattle when no one is in the seat. Before, it only squeaked with someone in the seat. 
May 2008

42000 mi

US $100
Seat squeak on passenger side. 
Ford Fusion in Ontario, Canada
Oct 2006 - Feb 2009
Dec 2006

3100 mi
Reflash PCM High idle speed at start up. No cost under warranty. 
Jan 2008

16120 mi
Vacuum lines under front dash in engine compartment would rattle when parked out in cold. Lines insulated and fastened securely as per TSB by Ford. 
Ford Fusion in Connecticut, United States
Sep 2006 - Sep 2012
Nov 2006

5000 mi
TSB for throttle response and transmission shifting issues. TSB for rattle on fire wall between 30 and 40 MPH. Rattle still present. 
Feb 2007

8000 mi
bumper adhesive let go on top of rear bumper 2 days after i bought the car 
Apr 2008

25000 mi
In for rattle in the rear of the car and previous TSB not done correctly (rattle on firewall). Blower motor clicking. Rattle fixed, TSB redone. Blower motor replaced. 
Nov 2008

34000 mi
Floor mat worn, dealer wouldnt replace it. Called Ford customer care, Ford required dealer to replace it. Still pending parts. Driver's seat torn, ordered new seat cover. Replaced torn seat cover. IMPROPERY INSTALLED. Had upholstry shop fix. Need to replace trim broken in the process. Do not plan to have dealer do next repair. Floor mats still not in. 
Aug 2009

44000 mi
CD player stopped working again. seat torn fixed 
Sep 2009

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. 
Ford Fusion in West Virginia, United States
Mar 2008 - Apr 2014
Sep 2009

53000 mi
Transmission slipping. Car went to shop and parts were ordered. They will be installed (new transmission) next week. Not under warranty. 
Jun 2011

75000 mi

US $465
Transmission slipping--cooling lines had to be replaced 
Sep 2011

78000 mi

US $150
Starter and battery replaced 
Jun 2013

84000 mi

US $387
Needed pads and rotors 
Ford Fusion in Ontario, Canada
May 2006 - Feb 2009
Dec 2006

6200 mi
squeaking brakes 
Oct 2007

12400 mi
Replaced lumber support, 
Nov 2008

19220 mi
Power window regulator faulty. 
Ford Fusion in Ohio, United States
May 2008 - Mar 2012
Sep 2008

18000 mi
The plastic trim on the moon roof that hides the gears disconnected from the window and interfered with operation of the moon roof.  
Oct 2008

24000 mi

US $50
The sunroof guards that hide the metal gears and parts had broken. The repair was fast and covered completely under warranty.  
Aug 2011

66000 mi

US $1300
Compressor needed to be replaced. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

Ford Fusion in Illinois, United States
Aug 2011 - Dec 2012
Nov 2011

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. 
Feb 2012

69000 mi

US $160
Accessory belt and belt tensioner replaced after tensioner began squealing regularly 
Ford Fusion in Pennsylvania, United States
Aug 2008 - Mar 2009
Mar 2009

45000 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. 
Ford Fusion in Florida, United States
Feb 2014 - Apr 2016
Apr 2014

128000 mi

US $5100
Piston rod bearing spun 
Apr 2016

167000 mi

US $680
Brake reservoir. Didn't fix problem now dealer wants 1100.00 to replace abs valve. 
Ford Fusion in Minnesota, United States
Sep 2006 - Mar 2010
Jan 2008

11000 mi
The grease used in the cv joints freezes below 20 deg so they replaced both axles. 
Ford Fusion in Kansas, United States
Dec 2009 - Jun 2015
Apr 2013

58700 mi

US $200
cooling, thermostant out 
Mar 2014

64000 mi

US $16
oil filter cover broke , replaced my self 
Ford Fusion in Ontario, Canada
May 2010 - Jul 2012
Jun 2011

69440 mi
front: brake pads and rotors, rear: just pads 
Ford Fusion in New Jersey, United States
May 2006 - Jun 2012
Mar 2008

32000 mi
Squeaky passenger seat when 200+ pound occupant aboard. Driver's seat heater element burned out and was replaced. 
Apr 2008

33000 mi
Seat squeek returned, will go back in the shop in May. 
May 2008

35000 mi
Plastic trim was rubbing on metal frame, was repaired by padding metal frame. 
Jan 2010

57300 mi

US $430
Replaced an engine sensor (and spark plug) due to a check engine light. 
Ford Fusion in Georgia, United States
Sep 2008 - Dec 2011
Nov 2010

79000 mi

US $300
Rear brake pads worn, replaced pads and rotors. Went with Ford OEM pads from parts dept at dealer where I work. 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. 
Dec 2011

96000 mi

US $120
Thermostat. Vehicle has had on and off problems with running too cold. P0128. Clunk in steering and during acceleration and braking. 
Ford Fusion in Alberta, Canada
Aug 2009 - Mar 2010
Sep 2009

2480 mi
Poor handling on slippery roads (rain/snow). Car sliding side to side at speeds higher than 60 K. Even in the winter with new winter tires. Info. via word of mouth from other drivers discovered  
Ford Fusion in South Carolina, United States
Jun 2010 - Jun 2011
Dec 2010

104000 mi

US $1300
Clutch went out. Throwout bearing failed. Starter. 
Ford Fusion in Michigan, United States
- Oct 2008
Oct 2008

50000 mi

US $1000
Bad plug coils 
Ford Fusion in Texas, United States
May 2011 - Oct 2014
Jun 2011

90000 mi

US $1750
complete rebuild of transmission assembly and casing 
Jul 2011

92000 mi

US $40
replaced side mirror control switch 
Aug 2011

92000 mi

US $40
replaced license plate bulb. took more than ten minutes, I'm a bit of a novice. 
Jan 2012

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 
Mar 2014

131000 mi

US $600
replaced pads and rotors for all 4 wheels 
Oct 2014

142000 mi

US $2800
Catalytic converter 
Ford Fusion in Texas, United States
Feb 2011 - Sep 2011
Jul 2011

74000 mi

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

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

Ford Fusion in Ontario, Canada
Jun 2013 - Mar 2016
Nov 2015

115940 mi

C $350
valve cover gasket replaced 
Ford Fusion in Alaska, United States
Dec 2006 - Mar 2010
Jan 2007

17000 mi
Replaced transmission 
Ford Fusion in Iowa, United States
- Jul 2007
Jul 2007

15000 mi
steering wheel radio functions wouldn't work correctly 
Ford Fusion in Michigan, United States
Feb 2008 - Apr 2009
Apr 2008

24500 mi
Driver side lumbar support on the seat broke. Replaced by dealership under warranty. 
Ford Fusion in Ohio, United States
Sep 2015 - Mar 2016
Oct 2015

30000 mi
Bought car with center vent broken / recessed into dashboard. Removed bezel around radio and upper cubby to access vent, reseat it into its facemount, and reassemble. No parts were broken or needed replacing, just realigned. 5 min job. 
Mar 2016

33000 mi

US $20
Upper dash pad delaminating from the underlying structure around the defroster vent, cracking the vent trim. Bought new trim piece at salvage yard and glued pad down with Loctite 410. Good as new. 
Ford Fusion in Iowa, United States
Jun 2006 - Mar 2016
Oct 2007

14000 mi
transmission range finder was faulty causing transmission and engine to rev at high speeds. 
Mar 2011

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). 
Mar 2012

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!! 
Ford Fusion in Ontario, Canada
Jul 2012 - Jun 2015
Sep 2012

53940 mi

C $200
Brake pedal went down all the way and brakes were very weak. The service shop said that they bleeded the ABS system and if it happens again will have to replace it. 
Nov 2012

55480 mi

C $100
Brake pedal went down all the way and brakes were very weak. Replaced master cylinder and ABS module covered under extended warranty. 
Apr 2013

59060 mi

C $100
Front turn signals stopped working. Had to replace and reprogram the smart junction module. 
Ford Fusion in New York, United States
Jul 2009 - Mar 2015
Sep 2009

74000 mi

US $400
check engine light on, an emissions valve was bad, expensive small part at $300 
May 2010

90000 mi

US $125
Original front brakes lasted 86,000. Unreal, this still remains a great car. 
Jul 2010

94000 mi
Rear brakes. 
Oct 2010

97000 mi

US $400
Oxygen sensor. Valve assembly. 
Dec 2011

111000 mi
Spring loaded idler pulley needed to be replaced. Replaced belt while at it. 
Ford Fusion in North Carolina, United States
May 2006 - Mar 2016
Oct 2006

7000 mi
drivers seat lumbar mechanism broken 
Jun 2011

130000 mi
MAF code, check engine light 
Jan 2013

172000 mi

US $500
Replaced thermostat to clear P0128 Code. Replaced front struts due to noises. Still may have to replace tie rod ends. 
May 2014

197000 mi

US $3500
Replaced, struts (4), front rotors and pads. A arms lower control arms (4), stabilizer links, tires o2 sensors 
Nov 2015

218700 mi

US $100
Battery 
Ford Fusion in New York, United States
Jul 2007 - Nov 2013
Nov 2008

26000 mi
The button to release the shifter did not pop out, leaving the shifter free to move up and down. 
Ford Fusion in Texas, United States
May 2006 - Jun 2011
Jun 2009

83000 mi

US $450
Thermostat change, oil change, tire rotation 
Feb 2010

99268 mi

US $500
Replaced throttle body 
Ford Fusion in New York, United States
Nov 2008 - Dec 2010
Mar 2009

33000 mi
Loose shift selector control handle. 
Jul 2009

35000 mi
Transmission "reflashed" due to "late shift" from 1st to 2nd gear upon startup when vehicle sat for more than 5 hours. 
Sep 2009

37000 mi
Rear brake rotors badly "warped" replaced at N/C by dealer-customer paid for brake pads. Both front headlight assemblies replaced as they were becoming "cloudy" (warranty)  
Ford Fusion in Iowa, United States
Jan 2010 - Dec 2010
Feb 2010

55000 mi

US $250
Thermostat 
Ford Fusion in Wisconsin, United States
Jun 2007 - May 2009
May 2008

21000 mi
Driver's interior door handle didn't work. Handle link broke, possibly from pulling too hard, but still covered under Manufacturer's Bumper-to-Bumper warranty. 
Ford Fusion in Oregon, United States
Nov 2014 - Mar 2016
Nov 2014

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! 
Jun 2015

70000 mi

US $467
Evaporator temp sensor was replaced, which involved removing the console and dash. 
Ford Fusion in Virginia, United States
Nov 2007 - Dec 2015
Jun 2008

39000 mi

US $285
Replaced canister vent valve assembly. 
Oct 2010

90000 mi

US $45
Driver inside door handle broke 
Feb 2011

98000 mi

US $360
wheel hub worn 
Apr 2011

101000 mi

US $500
Air pump valve replaced 
Aug 2012

125500 mi

US $465
Key would not come out of ignition. Replaced cylinder and lock 
Oct 2012

130000 mi

US $195
warped brake rotor, turned all 4 
Jan 2013

135000 mi

US $275
belt idle pulley became noisy. Replaced pulley and belt 
Mar 2013

139000 mi

US $370
lower control arm (front right) replaced 
Jul 2014

161000 mi

US $500
replaced left and right front cv axle shafts. Both had torn boots 
Aug 2014

162000 mi

US $1417
replaced front struts, worn Replaced driver seat track (power seat) 
Nov 2014

164000 mi

US $441
Replaced thermostat 
Feb 2015

166000 mi

US $162
clear air bag lamp and check system 
Ford Fusion in Arizona, United States
Jun 2006 - Feb 2015
Sep 2013

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). 
Feb 2014

110000 mi

US $1800
CV boot  control arms replacement 
Mar 2014

116000 mi

US $500
Replace brake pads and turn/resurface rotors 
Aug 2014

127000 mi

US $150
Resurfaced rotors were inadequately turned, and rotors were completely replaced for this trip. Shop put in replacement new brake pads under warranty (no cost). 
Feb 2015

141000 mi

US $400
Right axle, which had been replaced in February 2014, had another failure. 
Ford Fusion in Nebraska, United States
Jun 2006 - Dec 2015
Feb 2008

13000 mi
CD player would not function. 
Jun 2009

25000 mi
Creaking noise in front suspension Check engine light came on, problem was thermostat stuck open 
Jun 2012

59000 mi

US $800
Sensor in a/c system failed. Required removal of dash assembly to service. 30 dollar part, balance was labor. 
Nov 2012

63500 mi

US $180
Leaking valve cover gasket replaced. 
Ford Fusion in Virginia, United States
Jun 2010 - Apr 2013
Sep 2011

63000 mi

US $250
Check engine light indicated electronic thermostat was faulty. Replaced thermostat. Also changed front disc brake pads. 
Ford Fusion in California, United States
Dec 2006 - Feb 2009
Feb 2008

20000 mi
Gas intake problem. 

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2006 Ford Fusion 4-door

6-cylinder automatic 2WD

Ford Fusion in Alabama, United States
May 2006 - Mar 2010
Oct 2006

11000 mi
Upon starting the car, the gear shifter would not come out of park. This was accompanied by a strange combination of lights on the instrument cluster. Car would run, everything seemed to work, but it would not leave park. Email 2-8-2007: another trip where didn't fix transmission issue; two others where not actually written up, just disconnect and reconnect battery. See above See above 

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2006 Ford Fusion 4-door

4-cylinder manual 2WD

Ford Fusion in Ohio, United States
May 2007 - Aug 2008
Jan 2008

19000 mi
Driver's seat lumbar support broke. 

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2006 Ford Fusion Repair Histories

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.