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2006 Ford Fusion repairs by problem area

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Chart based on 254 repairs.

See TSBs and recalls for the 2006 Ford Fusion.

2006 Ford Fusion repair cost distribution

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Chart based on 198 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

See repairs for all Ford Fusion model years.

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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Ford Fusion in District of Columbia, United States Nov 2010 - Sep 2016
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 96400 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 131400 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 US $79	Replace top pulley and main serpentine belt
Sep 2016 165000 mi US $145	Alternator died, oil leaking on it from sensor seal on valve cover

Ford Fusion in Ontario, Canada Dec 2009 - Feb 2018
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 25300 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 68180 mi C $147	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 88440 mi C $700	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 Massachusetts, United States Mar 2011 - Jan 2012
May 2011 107800 mi US $195	technician found and replaced worn sway bar links. preventative maintenance, 100k service replaced spark plugs, flushed coolant system and transmission.
Aug 2011 115400 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	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 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 166400 mi US $3000	Computer went out and caused 3 coils to go out.

Ford Fusion in Vermont, United States Jun 2011 - May 2014
Jan 2014 137800 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 Ontario, Canada Jun 2011 - Mar 2018
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. Door latch not engaging properly on front right door, dealer had previously adjusted. Door closed but did not sit completely flush with body and door handle had extremely "light" touch. Some noise at highway speeds. Re-adjusted, 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 91860 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 90920 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.
Apr 2017 110980 mi C $550	Front left turn signal inoperative. Replaced smart junction box from wrecker, same year and trim. Fault with instrument cluster caused Ford passive anti-theft system to lock up and required a battery cable to be pulled for the car to restart. Problem also caused erratic gauge and MIL light behaviour until the car warmed up.

Ford Fusion in Saskatchewan, Canada Sep 2009 - Nov 2014
Nov 2010 81460 mi C $175	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 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.

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 Illinois, United States Feb 2009 - Nov 2015
Nov 2014 175000 mi US $340	Ignition coils replaced.

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 in Drivers seat broke. Manufactures Defect repaired under Original Factory Warranty. Lumbar support fixed

Ford Fusion in Texas, United States Aug 2009 - Jul 2021
Dec 2009 44000 mi US $100	buzzing noise coming from behind the steering column.
Jan 2011 53000 mi	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
Aug 2017 124000 mi	The wiring on left headlight is malfunctioning. Headlight goes off and/or wiring shorts out from time to time.
Nov 2017 128000 mi US $35	the connector on the headlight burned out. replacement of connector.

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 111440 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.
Feb 2013 101200 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
Sep 2015 137000 mi US $250	Window regulator fail

Ford Fusion in Connecticut, United States Jan 2006 - May 2023
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 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 North Carolina, United States Mar 2008 - Jun 2011
May 2008 34000 mi US $175	Replaced throttle body.

Ford Fusion in Ontario, Canada Jul 2016 - Jul 2017
Jul 2017 97340 mi C $530	Damaged tie rod. Also need to replace brake disks.

Ford Fusion in Minnesota, United States May 2010 - Mar 2019
Mar 2018 299000 mi US $750	Needed new shocks...they were the originals!
Mar 2019 315000 mi	Airbag recall

Ford Fusion in Kansas, United States Apr 2015 - Apr 2015
Jan 2015 80000 mi US $1800	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 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. 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. 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

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 Ohio, United States Dec 2014 - Jun 2022
Dec 2015 117000 mi US $20	front door handle broken. Got a part and fixed less than one hour Tie Rod end (both) boot torn. Replaced.
Jul 2017 124500 mi US $1	A/C not cool. Add refrigerant Right strut bearing made horrible noise. Injected lithium grease and all is fine.
Aug 2017 126000 mi US $80	strut bearing (front right) replaced.
Jun 2018 134300 mi US $100	all rear wheel bearings replaced
Jul 2018 136000 mi US $50	torque mount replaced
Aug 2018 137000 mi US $262	Driver side lower arms replaced. Squeak is gone

Ford Fusion in New Jersey, United States Jan 2015 - Jun 2022
Apr 2015 126300 mi US $420	Tensioner locked up destroying belt
May 2015 127000 mi US $750	Rust hole is rocker panel
Aug 2015 130000 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.
Jul 2021 172000 mi US $565	New spark plugs and coil

Ford Fusion in California, United States Apr 2015 - Jan 2017
Jul 2015 92000 mi US $1100	Replace tires, struts and shocks

Ford Fusion in Oklahoma, United States Mar 2016 - Jul 2016
Jul 2016 182000 mi US $480	Resistor connector melted which caused blower motor to not run.

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 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 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 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 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 Saskatchewan, Canada Jan 2007 - Apr 2015
Mar 2014 116560 mi C $2600	Overheated ignition coils, required computer replacement as per TSB.

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 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
Oct 2011 81000 mi	Bad O-Ring on new transmission was faulty, leaking all the fluid out of transmission and car woldn't run.

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 Ontario, Canada May 2006 - Feb 2009
Oct 2007 12400 mi	Manual drivers seat bolster stopped working. New one installed under warranty. Replaced lumber support,
Nov 2008 19220 mi	Power window regulator faulty.

Ford Fusion in New York, United States May 2006 - Jun 2015
Jul 2014 123000 mi US $40	license plate light fixture, state inspection item.

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 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 Oregon, United States Jan 2007 - Mar 2010
Mar 2007 12000 mi	Air leak in drivers window; door rattle; dash rattle

Ford Fusion in Quebec, Canada Nov 2006 - Mar 2009

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 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!!!!!
Dec 2011 64000 mi US $135	It was the thermostat. It failed to work.

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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 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 Michigan, United States - Oct 2008
Oct 2008 50000 mi US $1000	Bad plug coils

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 Alabama, United States Jul 2015 - Apr 2017
May 2016 100000 mi US $130	It ended up being the battery.
Aug 2016 103000 mi US $229	The damn door handle broke!!! 2nd time it's happened since I bought car new. First was under warranty period. Cheap ass plastic. The car will not lock when this happens & you have to roll window down to open the door. Irritating FORD!!!

Ford Fusion in Ontario, Canada Apr 2015 - Oct 2017
Oct 2016 92480 mi C $1000	Front struts worn out
Apr 2017 94240 mi C $200	Intake gasket
Sep 2017 95480 mi C $1000	Pads, rotors, calipers, front and rear

Ford Fusion in Illinois, United States Aug 2011 - Dec 2012
Nov 2011 66700 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 Georgia, United States Sep 2008 - Dec 2011
Nov 2010 79000 mi	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 Texas, United States Feb 2011 - Sep 2011
Jul 2011 74000 mi US $328	Thermostat stuck open. After diagnostic, problem confirmed. Thermostat and housing replaced.

Ford Fusion in Kansas, United States Dec 2009 - Jun 2015
Apr 2013 58300 mi US $200	cooling, thermostant out
Mar 2014 64000 mi US $16	oil filter cover broke , replaced my self

Ford Fusion in Pennsylvania, United States Jun 2019 - Apr 2025
Dec 2019 139000 mi US $550	Driver suspected Clutch issue. Turned out the R.R. Brake Pad fell apart and lodged causing drive and smell issues. Had car inspected for safety and repairs made.
Jun 2022 148000 mi US $500	Electrical connections for the clutch pulley of AC system had to be replaced. System charged. Also a new front driver side fender liner and side marker light from a previous incident.
Aug 2024 233447 mi US $200	R/R sway bar end link bad. R/F lower control arm with ball joint bad. Replaced both parts, then aligned at shop which was done for free. Then inspected.

Ford Fusion in Texas, United States May 2011 - Oct 2014
Jun 2011 90000 mi US $1750	complete rebuild of transmission assembly and casing complete rebuild of transmission assembly and casing
Jul 2011 92000 mi US $40	replaced side mirror control switch 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
Oct 2014 142000 mi US $2800	Catalytic converter

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 74400 mi US $430	Replaced an engine sensor (and spark plug) due to a check engine light.

Ford Fusion in South Carolina, United States Jun 2010 - Jun 2011
Dec 2010 104000 mi US $1300	Clutch went out. Throwout bearing failed. Starter.

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Ford Fusion in North Carolina, United States May 2006 - Sep 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 217700 mi US $100	Battery

Ford Fusion in Nebraska, United States Jun 2006 - Jun 2022
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 63300 mi US $180	Leaking valve cover gasket replaced.

Ford Fusion in Ontario, Canada Apr 2017 - Jun 2018
Jan 2018 104160 mi C $200	The back passenger brake caliper was sticking. I live in a Canadian climate where roads get salted every winter. The caliper piston was corroded and pitted. A friction ready replacement was much faster than attempting a piston replacement and not that much more expensive. I did both sides to avoid having to do the other next winter.
May 2018 106640 mi C $175	The transmission cooler line was corroded and leaking. It's not surprising considering the amount of salt we have on the roads here. The salt water collects in the plastic clip that holds the line and never gets a chance to dry out. After twelve years of that it failed.

Ford Fusion in Texas, United States May 2006 - Jun 2011
Jun 2009 83000 mi US $450	Thermostat change, oil change, tire rotation

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
Feb 2015 141000 mi US $400	Right axle, which had been replaced in February 2014, had another failure.

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 Virginia, United States Nov 2007 - Jun 2022
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 126300 mi US $465	Key would not come out of ignition. Replaced cylinder and lock
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 160300 mi US $500	replaced left and right front cv axle shafts. Both had torn boots
Aug 2014 162000 mi US $917	replaced front struts, worn Replaced driver seat track (power seat)
Nov 2014 163400 mi US $441	Replaced thermostat
Feb 2015 166000 mi US $162	clear air bag lamp and check system
Mar 2021 208000 mi US $370	replace alternator
May 2021 208000 mi US $51	replaced vacuum hose
May 2022 215400 mi US $1000	replace 4 brake rotors, calipers, pads, hoses

Ford Fusion in Iowa, United States - Jul 2007
Jul 2007 15000 mi	steering wheel radio functions wouldn't work correctly

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.

Ford Fusion in Alaska, United States Dec 2006 - Mar 2010
Jan 2007 17000 mi	MK: Initial repair for transmission speed sensor. Transmission damaged during repair, resulting in second trip reported by owner. Dealership damaged transmission replacing a speed sensor, which subsequently led to more damage when driven. Car returned to dealership and transmission was replaced. Replaced transmission

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 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 Iowa, United States Jan 2010 - Dec 2010
Feb 2010 55000 mi	Thermostat A week and a half later the car acted up again. Thought head gasket might have blown but turned out just needed to flush the cooling system.

Ford Fusion in New York, United States Jul 2009 - Apr 2020
Sep 2009 74000 mi US $400	check engine light on, an emissions valve was bad, expensive small part at $300
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.
Feb 2018 187000 mi US $1000	Replaced the original front CV shafts as well as rear wheel bears. Also front right wheel bearing.

Ford Fusion in Ohio, United States Sep 2015 - Dec 2017
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.
Jun 2016 36000 mi US $18	Front passenger side door handle broke off - new assembly installed, good as new.
Nov 2017 45000 mi US $5	Check gas cap light came on - cap was tight but gasket was hard and dirty. Replaced with OEM gas cap for $5 and light went away.

Ford Fusion in California, United States Dec 2006 - Feb 2009
Feb 2008 20000 mi	Gas intake problem.

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 Iowa, United States Jun 2006 - Jun 2022
Oct 2007 14000 mi	transmission range finder was faulty causing transmission and engine to rev at high speeds.
Mar 2011 54000 mi US $415	Thermostat inoperative 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 $130	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!!
Sep 2016 91000 mi US $235	belt tension er

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 55580 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 58360 mi C $100	Front turn signals stopped working. Had to replace and reprogram the smart junction module.

Ford Fusion in Oregon, United States Nov 2014 - Aug 2017
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 Ontario, Canada Jun 2013 - Mar 2016
Nov 2015 115940 mi C $350	valve cover gasket replaced

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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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Ford Fusion in Ohio, United States May 2007 - Aug 2008
Jan 2008 19000 mi	Driver's seat lumbar support broke.

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See TrueDelta's information for all Sedans

See TrueDelta's information for all Ford models.

2006 Ford Fusion repairs by problem area

2006 Ford Fusion repair cost distribution

2006 Ford Fusion

2006 Ford Fusion 4dr Sedan

2006 Ford Fusion 4dr Sedan

2006 Ford Fusion 4dr Sedan

2006 Ford Fusion 4-door

2006 Ford Fusion 4-door

2006 Ford Fusion Repair Histories