Worried about potential repair costs? An extended warranty can provide peace of mind.
Chart based on 178 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
2020 Ford Fusion 4dr Sedan
141-horsepower 2.0L I4 Hybrid CVT FWD
7000 mi
Replaced rear package shelf which had disintegrated. Warranty replacement
There's an annoying buzzing/rattling sound that seems to come from the front passenger side-the dealer has ordered new A-pillars to see if that eliminates the noise.
19000 mi
I noticed that water had gotten into the car (specifically into the cupholders) after it had rained a lot overnight. The dealer removed the windshield, reapplied sealant along the perimeter and reinstalled the windshield. No problems since then, and we've had even more rain.
Driver-side body panel trim (side skirt) under doors was loose. Required 4 trips to the dealer to resolve: 1. Identify issue and order part. 2. Went to install part, but discovered it wasn't painted! 3. Part is now painted, but they didn't have enough clips on-hand to install it! 4. Clips now in stock, part finally replaced and installed.
Sunroof has leaked since day one and they finally nailed down what the issue was. A bad seal. Of course it was after warranty so I have to pay.
56000 mi
The sun roof was finally replaced in the car to address the water leaks. Guess what, I still have a water leak. I literally have a steady drip action in the ran and every thrip into a car wash. The new roof also doesnt sit properly in the opening and the front driver side of it is noticeably lower than the rest and result in a little pond forming every time it rains.
There was a problem with the passenger door trim behind the a pillar (there was a TSB on it as well). Dealer had to order parts, fixed correctly the first time...
Backseat (probably inflatable rear seatbelt buckles) rattles at highway speed no matter the road surface. Couldn't replicate rattle in backseat. Window trim piece on driver's front unclipped (maybe broken). "Fixed" wrong trim piece.
10000 mi
Popping sound coming from underneath driver's side of the car. The dealer tried refastening a panel underneath the car.
12700 mi
Popping noise from underneath left side of the car. Unable to pinpoint and fix. They tried a few more things. Will attempt again in October.
13000 mi
Replaced Worn Steering Wheel
22000 mi
Inside of sunroof was rusted, no evident leaks.
36500 mi
Front and rear leather seats started to show wear. Both front leather seatbacks were replaced along with rear leather bench.
13200 mi
Spring in the rear seat grab handle above the window broke and needed to be replaced.
Plastic trim around sun visor fell off; plastic peg that kept it in place fell off.
23300 mi
Trunk hinges squeeked when opening and closing
47640 mi
C $200
Rear air vents broken.
55180 mi
C $600
Overhaed Counsole replace because glasses holder door broke...stayed open, would not close.
4000 mi
Headliner replace as per ssm 44717
43000 mi
The torsion spring that holds the left rear grab handle up against the headliner popped out of its seat, allowing the handle to hang down. I used a screwdriver and a needle-nose pliers to push the spring tail back into its seat. The job took less than half an hour and cost me nothing.
Window molding strips (in front of side mirrors) kept popping out. Dealership replaced entire window and black molding at a local glass shop. Headliner began showing yellow spots near the passenger side door due to manufacturing defect. Dealer tried spraying formula on spots with no results. Dealership and new-car warranty refused to pay for new replacement headliner.
12000 mi
Driver seat creaks/squeaks badly during acceleration and deceleration.
13000 mi
Second attempt to fix seat squeak. Part arrived (new chair foam. Started squeaking again within 24 hours. Took back in again for "good faith" visit and got a chair frame ordered.
10700 mi
TSB 13-05-03: Small plastic plates behind interior door handles are loose and vibrant constantly. Plastic panels were "fixed" with double-sided foam tape. Driver side visor clip broke, failing to hold visor in position. Dealer is reordering entire visor as the repair attempt failed.
14000 mi
The light inside the center arm rest was broken and pushed into the encasement preventing it from being functional. A clip on the replacement light was broken resulting in a reorder of the part.
5700 mi
Rattle/fast ticking coming from the rear interior door handle and door speaker area. Dealership reported they heard it and went into the door and taped something down and then took it on a road test. Returned to me with noise still there.
9000 mi
trunk liner not staying behind trunk gasket. "popped out". drivers door switch panel not sitting flush. "popped up". ticking in two rear doors. their first try did not fix it. I need to tell them about TSB 13-5-3. "panel behind handle hitting metal". That may fix it.
34300 mi
rattle in passenger door area. cup holder spring arms broken
23000 mi
door trim rattleing
32000 mi
Door latch failed.Part back ordered, hence the long stay
30000 mi
The passengers door panels rattles when the speakers hit a certain note.
19000 mi
Rattle in headliner. Re-wrapped wiring harness.
8300 mi
Various rattles in the interior as well that were not fixed.
16740 mi
Black plastic exterior trim on drivers door behind mirror came loose.Repair was attempted, but failed again.
The sunroof started opening and closing uncontrollably while driving. Heard arcing sound, smelled burning smell, pulled fuse. Dealer says motor was burnt out. Dealer replaced motor, but couldn't get new motor to initialize. Eventually just gave up with non-working sunroof since car had been at dealership for >2 weeks.
30000 mi
Fuel door hinge loose
4600 mi
Small trim piece on window near A pillar loose - both sides - replaced by dealer under warranty
Minor squeak coming from front end when driven over bumps. Dealer claimed to be unable to locate the source since it was intermittent.
53000 mi
US $234
Rattle from trunk area, repair attempted, unsuccessful.
27900 mi
Rattle inside headliner
19220 mi
Finish on passenger front door panel (closest to sideview mirror) came off after washing inside of window. All windows washed but only this area affected. Extensive delays from Dealership but finally replaced panel in December under warranty.
4960 mi
Hood ajar sensor would come on every time after opening and closing hood. Sensor was fine, hood was alighned and adjusted problem solved
24480 mi
Rear quarter window chrome trim fell off in car wash.rnNew pieces reinstalled by auto glass company via dealership. Done under warranty
27627 mi
Paint peeling on top of driver side side view mirror. Passenger side carpeting had small 2 inch rip in top right hand corner.
7000 mi
Plastic pillar moldings were coming off, dealer order a new replacement to be installed by the body shop team.
Fuel tank recall. And had them check for the electric cooling fan roar, and to fix the window trim that kept popping off on the front passenger's door... Went to another dealer as the dealer I bought it from(Galpin Ford) couldn't fit me in.
Fuel filler door not aligned correctly. Dealer replaced. Center console not fitting properly - caused by service to the car by another dealer - this dealer did not replace the trim properly. The interior gloss black piece containing the window controls and door handle was not seated properly in the door armrest of each of the car's 4 doors. This is apparently a common Fusion problem. The dealer attempted to fix, but could not.
13900 mi
Rear seat 120V power outlet was loose, plugs would not stay in place & would not make an electrical circuit
Passenger side sun visor clip was rattling. I remedied the issue by swapping the driver's side clip with the passenger side clip.
8000 mi
Left rear door didn't close smoothly, could be heard rubbing on frame. Door was adjusted to eliminate rubbing Incorrect shift knob installed by factory. Our car has the Luxury Package but the car was built with the base model shift knob. Dealer installed correct leather wrapped shift knob Headliner rattled near front of moonroof and passenger sun visor. Dealer discovered that a clip came from factory broken. Clip replaced, rattle is gone
9300 mi
Exterior trim panel not installed correctly from factory. There was a 2-3 mm gap between trim pieces on drivers side rear door that is not present on other doors. Trim panel replaced under warranty Left tail lens cracked in cold weather. Ford would not cover under warranty, so the dealer replaced at no cost to us
18000 mi
Exterior vertical trim pieces on both front doors were not installed correctly from factory and were loose, replaced under warranty Headliner rattle, another clip was broken and was replaced
1000 mi
Paint defects that were present at delivery
1500 mi
The chrome trim on the exterior rear quarter glass got detached and the rear glass (along with the weather strip/chrome trim) had to be replaced under warranty The plastic trim/cover that covers the interior C-Pillar was not fixed properly due to broken retaining clip. The retaining clip has to be replaced to fix the trim cover in place.
36000 mi
Plastic sun visor clip broke.
11000 mi
US $219
Wheel well liner over front right tire dislodged. Had it replaced.
4000 mi
Window Switches Gloss black came out of holder when shutting door.
5000 mi
They ordered a replacement plastic part that goes around all the windows switches. It's one piece and it was replaced June 15 approximately.
1000 mi
Paint bubbles present at delivery. Trunk lid repainted
8000 mi
US $20
Interior driver door vertical piano black trim was loose, trim was replaced under warranty Trunk squeaked when opening & closing. Trunk hinges were lubricated.
21000 mi
paint bubbling up on passenger side hood, leading edge due to corrosion under the paint
27000 mi
Paint bubbling on hood at site of previous dealer repair
Sun roof wouldn't open.They had to order a new motor for the sunroof.Day 2 was a Friday.Monday the motor sitill hadn't arrived finally on day 4 it was installed.Car was returned with soiled finger prints in 6 different areas.
driver interior door handle broke. DIY replacement
82000 mi
US $35
replaced inside driver's door handle
40300 mi
Rust on door rim (inside where the metal sheets are connected - probably leaking water) - covered repair under basic warranty by Ford - sand blasted by local body shop and repainted - lasted 2 weeks and rusting again...
61000 mi
US $25
Drivers side door handle broke. May have been covered by Ford warranty, but part was cheap enough to not bother with the dealer
Replace back and from left seat leather for unusual cracking. You only notice the cracks if you check the leather or sit on it, otherwise is difficult to see until is major.
14260 mi
Replaced SOP chrome trim above licence plate. I believe a mechanic touched the chrome piece while closing the trunk with some fluid on his hands that caused a chemical reaction. The film discolored and started to bubble up then peel.
Trim on buttons on right side of steering wheel was just slightly loose. Asked Dealer to replace not so much that it bothered me, but 1) technically a defect 2) didn't want it to break more in the future. Fixed and sturdy now.
22000 mi
Inside driver door handle broke, dealer replaced during initial visit to deal with problem.
25000 mi
Driver seat lumbar area was squeaking. Dealer had upholstery removed and insulation added so that the squeak stopped.
34000 mi
The dash was making a buzzing sound on hot afternoons. I noticed a piece of trim/bezel next to the radio stack was creaky on the left side but not the right side. Dealer firmed it up and so far it's better.
58000 mi
US $275
Rear interior door handle broke
4000 mi
a. Very slight drift to the right - tires rotated and balanced. No more problems
b. Rubber seal on back window was loose - repaired successfully by dealer
25000 mi
US $49
Moonroof became unseated. Dealer cleaned tracks and lubed. Fixed!
30000 mi
US $100
Drive side interior door handle broke. Replaced. (Seems to be a common problem).
56300 mi
US $168
Driver's door handle failed (2nd time). These are very cheaply made and apparently fail often.
Replaced weather stripping that was improperly installed from factory causing it to crack. Replaced trim piece in steering wheel that controlled volume, radio selection, etc. Part worked but was loose due to broken connector.
28300 mi
Broken piece on moon roof prevented it from closing properly. Broken trim piece on driver's seat.
30000 mi
Lose trim piece on steering wheel.
44640 mi
Sc button on the center stack console was pealing off. Dealer replaced the entire center stack console
45420 mi
Rattles coming for the dashboard. It took 3 trips to the dealer in order to get most of them out. A kit was installed by the dealer. Most of the rattles are fixed although once in a while I hear them. Driver seat and arm rest squeaks. After the third trip to the dealer got the issues resolved as the dealer lubricated the seat and arm rest.
Wheel covers damaged by an improper installation by the dealer after the first scheduled oil change and tire rotation. Two wheel covers were lost, the two remaining were damaged. Was told parts from problem had arrived. Showed up to our scheduled appointment to find that they were not in fact in stock and even more upsetting, had not been ordered. Scheduled another return trip. New wheel covers had been ordered and were replaced.
Replace passenger seat bottom leather which was curling/wrinkling; replace floor mats that said "mariner" instead of fusion Replace the chrome letter "I" in Hybrid that fell off the driver's side door; replace front Chrome grill that had the Chrome finish bubbling off already
8680 mi
Hybrid battery was loose in brackets causing a significant rattle. They removed the battery and re- seated it.
20460 mi
C $110
Inside driver side door handle broke (was not abused). The handle was replaced.
19000 mi
Moonroof water leak into cabin. Noticed water at several points in car (A pillar, headliner along top of door glass, maplight area) Seal determined to be defective. Replaced moonroof glass and seal.
38000 mi
US $110
Drivers interior (plastic!!) door release broke with normal use.
74000 mi
US $282
Drivers side interior door handle locking lever broke.
34000 mi
Rattle developed in dash from missing insulation between two overlapping ventillation ducts.
Replaced driver door lock mechanism and lever which were broken.
32000 mi
Paint bubbling on rear decklid immediately beneath chrome trim. Body shop sanding, priming and repainting under warranty.
50400 mi
US $50
For the second time, the trunk decklid was exhibiting bubbling paint and rust forming. Inexcusable, but our dealer offered to fix it for $50...
62000 mi
US $150
Second time the decklid has been in for repair. First time we had bubbling rust below the rear bright strip and was repaired under warranty (at 34,000 miles). Rust reappeared in the same locations requiring decklid replacement
I had them replace one of the small clips that holds the front bumper cover so it would not stick out (I was being picky).
27000 mi
Driver's side seat bolster has collapsed, causing the leather/ette cover material to rip and tear prematurely. Tear spot does not come into human contact. Told Ford would not cover it even though under the 3/36 bumper-2-bumper warranty.
3000 mi
Paint on exterior entry keypad was blemished. Passenger's air bag door on dash is warped and rippled. Dealer realigned and said that warp will disappear when door is heated by the sun.
59600 mi
US $2100
Moon roof track was broken and motor contained plastic shards from the track.
noise when window going down on drivers side, repaired with tsb for known concern. no charge to customer
4960 mi
Rear passenger cushion behind driver unable to support weight of occupant, deformation occurs that does not immediately dissipate when occupant exits seat. Advised by service adviser that although issue noted, unsure if can be fixed.
Car had become a piece of rusty junk with a failed transfer box. It was on it's way to the junkyard anyway, and I was able to help by bringing a large tree on it. Finished up looking like an El Camino.
I was hoping to donate the car to a missionary returning on furlough. I took the car in to get safetied and both rocker panels are rusted out. It will cost about $1200 CDN per side to pass the safety. Passing the safety is a requirement for transferring ownership of a vehicle in Canada if the buyer intends to license the car for use on the road.
3100 mi
trimming around the door was loose
11160 mi
Rear doors are hard to close, I have to reopen it after a unsuccesful close a lot more often than any other car I ever used, they changed a part and tweaked the other door, it's still the same, they can't do anything more. The car in show room is the same
Been to dealer once regarding rattling drivers door panel. They changed the speaker and put foam tape on the door panel edges, and noise hasn't returned. Took approximately 1-2 hours.
47000 mi
I had rust under the hood lip, trunk lip and drivers side rear door.
19000 mi
Door wind noise. Dealer adjusted door seal.
34000 mi
Drivers seat cushion material developed crack in material. Dealership inpected and immediately ordered/replaced with new seat cover. Warranty repair.
buzzing noise coming from behind the steering column.
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.
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.
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.
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.
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.
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.
109740 mi
C $500
replace moonroof motor to open and close. Checked fuses and contact switch for functioning and both were not the problem.
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.
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.
135160 mi
C $350
remove motor to sun roof and close sunroof permanently.
12000 mi
Air leak in drivers window; door rattle; dash rattle
117000 mi
US $20
front door handle broken. Got a part and fixed less than one hour
24000 mi
Passenger seat squeaks loudly when occupied. Dealership has not been able to resolve after 4 trips.
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.
42000 mi
US $100
Seat squeak on passenger side.
15000 mi
Had TSB 07-05-10 for wind noise at the B pillar performed.
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
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.
12400 mi
Replaced lumber support,
46000 mi
US $40
Driver's inside door handle broke. Replaced the door handle mechanism.
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
80000 mi
US $350
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
9000 mi
Noise from driver side door.
2000 mi
Squeaky pass. seat when someone is sitting in it and on left turns.
34000 mi
Lumbar support fixed
5000 mi
TSB for rattle on fire wall between 30 and 40 MPH. Rattle still present.
8000 mi
bumper adhesive let go on top of rear bumper 2 days after i bought the car
25000 mi
In for rattle in the rear of the car and previous TSB not done correctly (rattle on firewall). Rattle fixed, TSB redone.
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.
Squeaky passenger seat when 200+ pound occupant aboard.
33000 mi
Seat squeek returned, will go back in the shop in May.
35000 mi
Plastic trim was rubbing on metal frame, was repaired by padding metal frame.
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!!!
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.
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.
36000 mi
US $18
Front passenger side door handle broke off - new assembly installed, good as new.
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.