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%)

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

Ford Fusion suspension repair cost distribution

$2500+ (4%)

$1000 - $2499 (14%)

$500 - $999 (22%)

$100 - $499 (42%)

< $100 (19%)

Chart based on 79 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 240hp 2.0L I4 6-speed shiftable automatic AWD

24800 mi I curbed both wheels on passenger side. (snow problems) 
9000 mi One wheel had a rattle when turning right. Unsure what was done to fix it, but it was a very minor problem. 

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2015 Ford Fusion 4dr Sedan

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

Front strut defective, started leaking. Replaced under warranty. Loaner was provided. 

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2014 Ford Fusion 4dr Sedan

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

29000 mi Rear left hub bearing replaced. 

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2014 Ford Fusion 4dr Sedan

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

18000 mi

US $250
Noticed right rear ball bearing noise, took to shop. Found bent right rear rim, replaced bearings and re-aligned. Covered under insurance. Days later noticed front bearings needed to be replaced. Covered under warranty. 
18250 mi Replaced rear passenger shock and mounting bracket because of metallic noise over potholes. Problem still present. 

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2014 Ford Fusion 4dr Sedan

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

17000 mi Power steering (and traction control) went out one day. Dealer replaced a steering gear. 

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2014 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

38000 mi

US $140
leaking shock absorber 

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2013 Ford Fusion 4dr Sedan

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

30380 mi Replaced rear shocks 
58000 mi

US $300
Left front wheel hub assembly broke. 

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2013 Ford Fusion 4dr Sedan

turbocharged 178hp 1.6L I4 6-speed manual FWD

26000 mi

US $86
Knocking noise from steering during parking lot maneuver. Steering bolt broke and replaced but parking assist still inoperative. Navigation unit frozen. Reprogram navigation and my ford touch system. Airbag control and door latch recall. 
29000 mi replaced electronic power steering system to resolve parking assist. Did nit resolve the issue due to software incompatibility with manual transmission. 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

26000 mi Power steering failure 
10300 mi Steering clunk when backing up, turning right and gently applying the brakes. Dealer could hear sound but doesn't know what's causing the clunk. They claim it's nothing to worry about 
19000 mi Steering clunk, axle replaced. Didn't fix. Clunking sound present, TSB called for adding some shims to wheel hub. Noise fixed. 

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2012 Ford Fusion 4dr Sedan

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

124000 mi

US $100
Bad wheel bearing-replaced 
22900 mi

C $50
Sensor failed. To replace sensor needed to replace steering gear. Would have been $2,400 if the extended warranty hadn't paid. 
20000 mi Clunk from left front when hitting dip in road while turning and braking. Dealer reproduced at first but nothing found when inspecting the suspension, but later could not reproduce noise at all. Got car back and issue returned in a day. 
75000 mi

US $100
Front upper shut mounts were making noise when the wheel was turned in parking lot maneuvers. After upper strut mounts were replaced, the noise was still present. 
77000 mi Suspension noise never fixed. 
38000 mi

US $600
Both lower control arms replaced due to worn bushings. (bushings are press-fit into the arms, and cannot be replaced separately) 

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2012 Ford Fusion 4dr Sedan

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

2320 mi Loss of power steering, known EPAS issue, steering box replaced under warranty 
109120 mi problem with sway bar blots for toe wheel adjuster ect. 

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2012 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

37000 mi My car began making a 'knocking' noise at low speeds when stopping, accelerating or turing when temps reached 80F. Turns out it was defective front control arms. Dealer was nice - giving me an extension of the warranty so I had $0 to pay. 

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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 

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2011 Ford Fusion 4dr Sedan

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

13700 mi Car pulled to the left. Had to replace a control arm. 

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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. 

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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. 

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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 
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

104000 mi

US $520
Loud creaking in front-end at slow speeds. Replace all four lower control arms. 
65000 mi

US $100
Steering wheel rack failure which made the power steering inoperative 
49000 mi

US $205
Right front lower control arm ball joint failed inspection. 
36500 mi strut clunking 

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2010 Ford Fusion 4dr Sedan

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

96300 mi Rack and pinion was leaking from the boot. Completely replaced rack and pinion under extended warranty. However had to pay for system flush and alignment out of pocket. 
27700 mi Steering briefly shuttered and groaned during a full turn - per service manager, problem found was loose power steering hose resulting in low fluid. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

139000 mi

US $1100
Front spring cracked. Replaced both springs and struts 
43400 mi 19-Oct-10 35500 km Problem detected when I saw lubrication fluid spots under car while parked in my driveway. Driver side front axle seal gone and leaking fluid. 
99820 mi

C $2234
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. 
105400 mi

C $150
Both wheel bearings replaced 
124000 mi

C $300
Both sides have tie rods with excessive play in them. 
21300 mi Rear suspension would 'bottom out' on almost any sized bump. Took to dealer; they determined that both of the rear shocks were leaking. Shocks were replaced under warranty. 
153760 mi

C $637
replace both outer tie rods 
60300 mi bearings replaced - took to shop some months prior but mechanic didn't hear the noise so no action. This time they did. 
4960 mi The car had to be taken in several times for them to diagnose and fix the problem, also the dealership caused a problem while fixing the first issue 

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2010 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

87700 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. 
64000 mi

US $650
Cracked wheel bearing; made a grinding noise when making turns. 
58000 mi

US $460
Bent wheel bearing replaced. 
54000 mi Right-front wheel bearing was making a little noise on slow turns but was otherwise unnoticed. 
97300 mi

US $95
Power steering and AdvanceTrac systems flashed warning lights. Car automatically disabled power steering and AdvanceTrac. Dealer reset warnings, recommended replacement of steering rack. 
90000 mi

US $300
tie rod replacement 

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2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

130000 mi

US $200
Left front wheel bearing required replacement. 
3000 mi car drifts to right 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

83700 mi

C $500
Replace 2 front wheel bearings 
155000 mi

US $216
Bolt on upper control arm (passenger side) came loose and resulted in clunking sounds. Mechanic tightened it and checked all suspension bolts. 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

33000 mi There was noise and vibration coming from the steering column at times. Dealer tightened hose connection on power steering pump and added more fluid. 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

105000 mi

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

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

51920 mi

C $250
Blown steering line - hose had rubbed through. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

82000 mi

US $215
Replace both tie-rod ends 
52000 mi

US $350
Front and rear sway bar end links worn out causing a rattle going over uneven surfaces. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

118000 mi

US $1000
Replace both tie rod ends. Steering wonky. replace sway bar links - front. Making noise 
136300 mi

US $100
rear shocks worn out (rear end very bouncy whenever even light load present), replaced shocks 
85000 mi

US $753
Replaced front shocks trying to eliminate a suspension noise. Noise still present after shock replacement so greased left ball joints as best as possible (since there are no zerks) and noise went away after about a week. 
96000 mi

US $200
Replaced control arms to resolve ball joint creaking noise issue 
80000 mi

US $250
Drivers side front lower control arm replaced due to noisy bushing. 
80300 mi

US $300
Replaced rear shocks because they were blown. They were worn out a little prematurely because the car is slightly lowered. 
186000 mi Wheel bearings, front. 
197000 mi Wheel bearings, rear. Power steering pump and pressure hose. 
206000 mi Power Steering pressure switch failed. 
119300 mi

US $100
Tie rod bushing and axle boot ripped. Probably caused because car has been lowered for almost 100k miles 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

119000 mi

US $230
Squeaking and uneven tire wear caused by worn out struts. Replaced front struts and rear shocks. 
168000 mi

US $200
Right front wheel bearing 
109740 mi

C $200
Ball joint went, replaced entire control arm as it was easier. 
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 
47120 mi

C $1600
Replace wheel bearings front and rear. 
31000 mi A bearing went out in right rear axle. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

122000 mi

US $1100
rear upper control arm struts and shocks 
65000 mi

US $300
Left axle shaft (that turned out to not be the problem) and left front wheel bearing. 
55180 mi

C $340
There were clunks when entering driveways etc. 
104300 mi

US $260
Right front wheel bearing replaced 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

98000 mi

US $1200
Tie rods replaced 
30000 mi

US $810
Steering pump had to be replaced, making strange sounds. 
97000 mi

US $58
Mechanic noticed issue. Dealer replaced control arm. 
119000 mi

US $770
Front right control arms wore out and needed to be replaced. 
129000 mi

US $770
Front left control arms wore out and needed to be replaced. 
6820 mi Suspension sounds wrong. 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

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. 
97700 mi

US $560
Both front hubs replaced, passenger hub mount also replaced as hub was seize-rusted on. Also replaced oil pressure switch. 
142000 mi

US $300
rack and pinion replaced with used oem 
92000 mi

US $1100
Replace tires, struts and shocks 
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!!!!! 
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. 
88640 mi

C $700
Replaced both tie rod ends. Replaced right side upper ball joint. 
109000 mi

US $195
technician found and replaced worn sway bar links. preventative maintenance, 100k service replaced spark plugs, flushed coolant system and transmission.  
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. 
123380 mi

C $350
struts replaced. 
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 
82000 mi suggested replacement of bar. repair too expensive, so I decided against the repair 
103000 mi suspension creaking. mechanic idicates the control arm may need to be replaced 
122000 mi

US $20
Tie Rod end (both) boot torn. Replaced. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

96000 mi

US $120
Clunk in steering and during acceleration and braking. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

172000 mi

US $500
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 
110000 mi

US $1800
control arms replacement 
98000 mi

US $360
wheel hub worn 
139000 mi

US $370
lower control arm (front right) replaced 
162000 mi

US $500
replaced front struts, worn 
25000 mi Creaking noise in front suspension 

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Ford Fusion Suspension Problems

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