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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 1554 repairs.

Ford Fusion transmission repair cost distribution

$2500+ (8%)

$1000 - $2499 (11%)

$500 - $999 (23%)

$100 - $499 (39%)

< $100 (19%)

Chart based on 64 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2016 Ford Fusion 4dr Sedan

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

9700 mi AWD failure indication. 

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2014 Ford Fusion 4dr Sedan

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

15000 mi Harsh shifting Trans, missing Rev matches, and occasional hesitation. Also radio volume increasing with no driver input. Supposedly dealer performed PCM software update and reflash of My Ford touch software. Volume:fixed, Trans: not fixed 
6000 mi Various parts needed to be replaced inside transmission due to slippage in first three gears. Problem was aggravated by the cold weather. 

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2014 Ford Fusion 4dr Sedan

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

31000 mi Drivetrain repair 

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2013 Ford Fusion

Engine not specified

8000 mi Slips between 1st and 2nd gear, Left it at dealer for a few days and If the computer does not give error code or check engine light they cannot do anything about it. It is obvious that it slips and sounds different between 1st and 2nd gear. 

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2013 Ford Fusion 4dr Sedan

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

9000 mi when shifting from forward to reverse (or vice versa), clack or click sound from front wheels. Sounds similar to pads sliding around in caliper, but is NOT that. Found TSB 13-5-24 on blue oval forum. Needs thrust washers on half shafts. 
25000 mi There is a "squish, squish, squish" rhythmic noise coming from the drivers side, noticeable coasting at 10mph with the window down. Sounds like is coming from driver front wheel. 
32500 mi rhythmic noise from drivers side still there 
43000 mi Clicking noise from front left while turning. Dealer diagnosed as differential problem. Differential replaced, but problem returned within a day of picking up the car. 
44000 mi Clicking noise remained after differential replacement. Dealer found TSB for CV axle replacement. Driver side CV axle replaced. 
7000 mi Clicking noise when putting into drive. Replaced thrust washers in transmission. There was a TSB for this repair 
31000 mi would get stuck in 2nd gear. 2-3 shift hard. 
7700 mi Transmission valve malformed and popping when put into reverse. 
22700 mi Half shaft TSB 
20460 mi Replaced defective part 
12000 mi TSB performed for CV click with thrust washer. Took dealer "forever" to source parts on common repair. 

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2013 Ford Fusion 4dr Sedan

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

40000 mi Transmission shifts harshly, most noticeable in the 2->3 shift. The transmission learning memory was reset. The harsh shifting was lessened, but not removed, for a while but seems to be returning. 
26000 mi repaired oil leak on axle boot 

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2013 Ford Fusion 4dr Sedan

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

21080 mi Transmission software updated 
26000 mi The car went into sort of limp mode and I was not able to accelerate over 2000 rpm. A wrench symbol popped up on my dash which indicates transmission issues but goes away when I turn off the car. 
42500 mi

US $680
leaking seal on the drive shaft exiting the transmission 

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2013 Ford Fusion 4dr Sedan

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

38500 mi When car is cold, car shifts hard from 4 to 5 
44000 mi Reported problem in April 2014 continued....When cold, car would jerk when shifting 4 to 5th...Vista Ford of Oxnard took tranny out and replaced a solenoid assembly...Was a Technical Service Bulletin...... 
46000 mi Problem still present even after Fourth of July repair..Vista Ford of Oxnard rebuilt tranny, meaning replaced valve body and clutches and flushed cooler lines due to debris..... 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

6000 mi Ice had gotten into the fuel filler neck and triggered check engine light. Dealer melted ice and cleared codes. No real way to prevent in future as this is a design flaw. 
19000 mi PCM needed to be replaced because it died. 
8000 mi

US $20
Transmission is leaking. Dealer claims that it is just "seeping" and not dripping and thus there is "no problem". They consider the huge wet spot on the panel to be "normal". They ignored the Ford TSB about this issue. 
8000 mi Transmission seal seeping. 
4000 mi Clicking noise from front half-shafts - fixed as part of TSB for both left and right side 
16300 mi Transmission seal leak (eCVT) . Known issue for some hybrids, repaired under warranty. 

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2012 Ford Fusion 4dr Sedan

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

8680 mi Tranny shifting rough. Axle seal leak discovered. Replaced 
32200 mi Erratic shifting 
4000 mi vehicle is not shifting correctly, slamming gears and over revving between shifts vehicle still not shifting properly, data recorder was installed then removed after a few weeks. 
34100 mi transmission seal defect, transmission was leaking 
47120 mi transmission seal again!! on warranty 
59000 mi

US $100
Right front axle seal was leaking. Repaired under Ford extended warranty. $100 deductible. 

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2012 Ford Fusion 4dr Sedan

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

44640 mi Vibration in drivetrain at 89 t0 80 km car is with ford Engineering had problem with this at 269 km when car has new been fighting for two years. need help. Update: replaced driveshaft with updated part. 
78960 mi same vibration in drivetrain and transmission slipping and banging, everthing but the engine was changed still have the samr problem. 
84320 mi same on going problem with transmission slipping and vibration in drivetrain. axle replaced, was making a noise 
92380 mi axle and steady bearing on going problem with this car, still have transmission vibration. 
99200 mi after another attempt, transmission slipping and big loud bang from drivetrain. happened on the highway. doesn't seem safe. 
104160 mi vibration in drivetrain. transmission, brakes, trans slipping and banging engine 
104760 mi

C $80
Had transmission rebuilt again and driveshaft replaced again. 
9700 mi SUM: WHEN NEW, VEHICLE EXHIBITED HARSH SHIFTS FROM 1-2. GRADUALLY WORSENED AND CAME TO INCLUDE A SOFT 2-3 SHIFT AND A METALLIC FRICTION NOISE IN LOWER GEARS BY 1000MI. STARTING AROUND 7000MI, VEHICLE STARTED TO SHIFT ERRATICALLY IN TRAFFC 

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2012 Ford Fusion 4dr Sedan

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

4000 mi Erractic shifting/slipping. Reprogrammed powertrain computer 
13000 mi Erratic shifting, shift flares harsh shifts. 

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2012 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

11300 mi Harsh shift 1-2, slipping and flaring 2-3 and 3-4 despite application of TSB 12-3-7 Failure of valve body due to worn regulator valve bore. Total rebuild with replacement of all clutches, gaskets, and seals, including foward, reverse, overdrive clutches and final drive seal. Vehicle in shop for 21+ days. 
18000 mi Further work up for harsh 1-2 shift, now only when cold. Vehicle pressured tested and passed. PCM update applied. 50 percent improvement. 
31000 mi Continued harsh 1-2, flared 2-3, and other shift quality issues. 
6670 mi Transmission adjustment 
10700 mi Transmission software adjustment 
16000 mi Automatic transmission not shifting correctly. 
24000 mi Automatic transmission not shifting correctly 

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2011 Ford Fusion 4dr Sedan

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

52000 mi Trans was shifting hard at times going into second. 

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2011 Ford Fusion 4dr Sedan

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

45500 mi Transmission operation was very displeasing. Hard shifting, hunting for gear, gear hopping when stopped in gear, so on. Taken to dealer, supposedly the TCM was updated to the latest software (TSB). Issues continue, but to a much lower degree. 
86000 mi Odd shifting habits and other strange transmission behavior. Changed fluid again with a different type just prior to accident which took car out of my possession. 
51000 mi

US $730
Front right axel 
25500 mi

US $734
Firmware update to improve shift quality. 
14000 mi Transmission slipped between 2nd and 3rd. Software update. 
16000 mi Transmission slips in change from 2 to 3 when cold. Told this is normal by dealer. 

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2011 Ford Fusion 4dr Sedan

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

37000 mi Transmission was shifting hard. Dealership couldn't find any issues, however they reprogrammed the transmission computer. This fixed the problem. 

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2011 Ford Fusion 4dr Sedan

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

38000 mi Axle seal for right drive shaft 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

44000 mi

US $250
Shifter broken. It is going to cost $400 to replace it. I have been trying to convince Ford to pay for the replacement since it failed with only about 43,000 miles. So far it has not agreed to it. 
32000 mi Heavy clunk when shifting from park into reverse or reverse into drive. 
9300 mi Occasional Hard shifting 
24000 mi Slams into 3rd gear when cold. Retimed shift points. 

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2010 Ford Fusion 4dr Sedan

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

59000 mi

US $80
Car made grinding noise when turning right. Replaced the driver's side CV axle myself (after watching YouTube video). 
28300 mi Replaced rear seal transmission 
50000 mi Black and burned transmission fluid requiring flushing 
9000 mi Transmission replaced but didn't solve problem: slipping while going uphill, hard shifting. New transmission removed twice, replaced valve body, solenoid, and PCM, still didn't solve problem. Hav refused offer to replace trans again, want buyback. 
11000 mi I finally agreed to allow Ford to install yet another transmission. This one at least appears to have resolved the issue. 
18000 mi The transmission slammed into reverse. I have had and apparently continue to have problems with my transmission.  
55000 mi I was getting some random, intermittent shift-slippage that would have led me to take the car in for service had I not traded it in. 
8000 mi Transmission started slipping upon heavy acceleration, took into Ford dealer who were not easy to deal with.... Next day they said they were replacing valve body - common failure among 6F35 transmission. 
10000 mi Car came back with a transmission whine upon running at full operating temperature. Transmission fluid level was also found too high, but that did not relate to the whine, car still has to go back. 
18000 mi Transmission is still acting up, hasn't been right since 1-2010, dealer cannot fix it. 
19000 mi Car is a lemon - faulty transmission since January 2010 
22000 mi Transmission was slipping severely and "whining". Car went in for transmission overhaul and after a week problems are just as bad again. 
26000 mi Transmission whining, very obvious and everyone BUT Ford dealer acknowledges it. 
32000 mi Transmission failing to shift on highway. Severe slipping and banging. Failure to reset to 1st gear at stops when coming off highway 
73000 mi

US $200
Recall to recalibrate Throttle Body Sensor. 
110360 mi

C $600
My 2010 Fusion was leaking transmission fluid, turns out the left axle seal was bad and they had to replace the whole unit. 
23000 mi

US $89
hard shifting, re programmed software. 
12300 mi Overdrive piston in transmission problem - replaced under warranty along with ancillary parts. Basically a significant transmission service/rebuild. Problem was missing gears during acceleration. 

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2010 Ford Fusion 4dr Sedan

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

80000 mi

US $237
Had to re-flash the transmission due to rough shifting. 
19840 mi Drivetrain noise when shifting from reverse into drive, and failure of transmission to 'kick down' when accelerating from stationary position within reasonable time period. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

36000 mi Complete replace of transmission 
1000 mi Manual Transmission failure. Transmission was replaced. 
33300 mi Grinding gears when shifting from 1st to second at high rpms. 
39000 mi Occasional grinding shift from 1st to 2nd gear 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

51000 mi codes p0753,p0219,slipping in 4th and 5th gear; remove transmission and overhaul unit; transmission fluid leaked allover my drive way returned to dealer for further repairs 
31000 mi transmission acting weird @below 5km/h in stop and go traffic when engine is hot. 
56000 mi Transmission hard shifting. Reflashed computer, and fixed shifting problem. However, it was leaking transmission fluid. Ended up replacing the half shaft (under warranty), as it was cracked. 
1900 mi TSB installed to correct transmission "flairing" when cold. TSB was successful. 
10000 mi Complete transmission replacement; covered under warranty. 
37000 mi

US $210
Engine check light. Dealer said error was for transmission and firmware update fixed it. 
93000 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 
99700 mi

US $400
Transmission leak found. Replaced drivers axle seal 
94860 mi

C $275
Transmission lines were rusted and leaking in 2 location. New transmission lines installed. 
128700 mi

US $10
Driver side bushing and seal replaced..Was leaking trans fluid.... 
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." 
23000 mi Half Shaft Transmission Fluid Leak 
22000 mi Recently noticed a leak under the car and my RPMs jumping as I accelerate. Turns out my axle seal needs to be replaced and transmission fluid is leaking. According to the service mgr (and what I read on the internet), Ford is aware of it. 
34000 mi Transmission shifted hard on occasion. Car would fail to downshift gradually as I coasted to a stop, leaving me with no torque, then would slam down into gear. 
69440 mi

C $707
Transmission fluid leaking; installed joint and stub shaft, replaced axle bushing and seal. In my view it seemed to be a factory defect and not a usual maintenance repair. Dealer did not want approach Ford for partial reimbursement. 
31700 mi Intermittent transmission problem. Jumps out of gear at high speeds (around 70 mph). Dealer not able to replicate. Third time in for repair. 
24000 mi Experienced hard shifting from 1-2 and 2-3. Shift flare from 3-4 at times. Reprogrammed PCM as per 3 TSBs. Repair seemed to help the issue, but not completely resolve it. Returned from ~1,000mi round trip. Hard shifts and shift flaring returned. Took to dealer, was notified that transmission would have to be replaced. Overdrive clutch and others burnt up. Fluid was black. Replacing torque converter & trans. 
11000 mi Transmission problems - clunking noise/feel when changing gears. Shop could not replicate nor did codes show anything wrong so nothing was done. 
75000 mi Transmission would clunk when slowing down and started shuddering when accelerating or decelerating. Dealer could find nothing wrong. It had this problem since 25,000 but became more and more frequent. 
21000 mi Took it in for harsh 2-3 shift and intermittent RPM flare between same shift. Was told could not duplicate. 
23000 mi Took back to dealer a few days later after voicing displeasure with last repair trip. They kept the car for 4 days and still told me they couldn't duplicate the problem. Less than pleased with Ford and this troublesome 6F35 transmission. 
46400 mi Replaced leaking axle seal as instructed by TSB 
26940 mi Right front axle seal leaking. Removed RF wheel. Disassembled front end, left lower ball joints intact. Removed axle. Removed and replaced seal. Reassembled front end. Replaced axle nut and torqued to spec. Topped up trans oil. 
34000 mi harsh shifting, trouble finding the right gear 
42000 mi Continued Harsh Shifting/Skipping, lack of power 
51000 mi Occasional "flare" (momentary increase in rpms as if missing a shift with a std. trans.). This didn't happen very often though. 
59000 mi transmission fluid leak was detected when I went in for an oil change. There is a TSB on this, leak on left side, and some parts were replaced. 
27000 mi The transmission was shifting from 3 to 4 harshly. The dealer reprogrammed the automatic transmission and that seems to have worked. 

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2010 Ford Fusion 4-door

4-cylinder automatic 2WD

68700 mi car is pulled by RV. 4 WHEELS down. I follow Fords instructions. this is 2nd transmission in 10 months. car is still not ready. 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

16000 mi transmission shifting poorly and leaking fluid...pan will be resealed and OSS must be replaced. 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

76240 mi

C $800
I lost almost all transmission fluid. The indication was a burnt smell in the car. Was able to take the car to the dealer. They change tubes running from the transmission to radiator and did flushing transmission for 800$. Transmission saved 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

38000 mi Carrier bearing failed on the driveshaft (AWD). Entire driveshaft was replaced as a result. 
76000 mi

US $829
Replaced rear driveshaft due to failed front carrier bearing. 
29140 mi Moaning noise under power coming from behind driver. Diagnosed by Ford mechanic as a bad hanger bearing, drivershaft replaced, one day wait on parts. 

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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

69700 mi

US $320
Torn CV Boot 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

113000 mi

US $200
replace leaking transmission cooler lines that run to the radiator, Slow leak. Showed a red spot under that car when parked overnight. 
143000 mi Transmission replacement. 
180000 mi Transmission linkage repaired--would not shift out of drive.  

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

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 
50000 mi Coudy transmission fluid. Occassional harsh shift. Per Ford TSB internal transmission component changed and PCM reprogrammed. Car was driving OK when dropped off, but the transmission fluid was very dirty. 
101360 mi AWD car, half shaft joint went, had to replace shaft. 
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. 
140000 mi

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

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

79000 mi

US $80
Manual trans wouldn't go into gear. Trans fluid change resolved issue 
37200 mi

C $140
Difficulty shifting. The problem is mostly experienced when the car is cold and when shifting into 2nd (this is a manual transmission). 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

19000 mi Transmission abruptly downshifts at time. Dealer could not find anything wrong. 
126000 mi

US $120
CV boots have been cracked for about 30k miles. Finally replaced them. They were NOT making any noise. 
60000 mi

US $281
Passenger CV axle boot torn 
62000 mi

US $75
Engine diagnostic indicated I needed to replace a sensor in the transmission; a Ford Tech said I should just flush the transmission fluid and replace the filter. Replaced the transmission fluid and filter. 
67000 mi

US $180
Had recurring engine code P0772 shift solenoid E stuck on. Ford mechanic said transmission fluid flush usually solved problem; not so. I replaced the E solenoid, did another fluid flush and replaced transmission filter. 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

104160 mi

C $300
Transmission lines replaced (leaking fluid). 
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). 
53000 mi Transmission slipping. Car went to shop and parts were ordered. They will be installed (new transmission) next week. Not under warranty. 
75000 mi

US $465
Transmission slipping--cooling lines had to be replaced 
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. 
134000 mi

US $400
Trans cooler lines rusted through and were leaking 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

11000 mi The grease used in the cv joints freezes below 20 deg so they replaced both axles. 
90000 mi

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

US $500
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 
104000 mi

US $1300
Clutch went out. Throwout bearing failed. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

14000 mi transmission range finder was faulty causing transmission and engine to rev at high speeds. 
17000 mi Replaced transmission 
33000 mi Loose shift selector control handle. 
110000 mi

US $1800
CV boot  
142000 mi

US $400
Right axle, which had been replaced in February 2014, had another failure. 
161000 mi

US $500
replaced left and right front cv axle shafts. Both had torn boots 
26000 mi The button to release the shifter did not pop out, leaving the shifter free to move up and down. 

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2006 Ford Fusion 4-door

6-cylinder automatic 2WD

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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Ford Fusion Transmission Problems

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