Ford Fusion Ford Fusion

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Ford Fusion repairs by problem area

Engine (25%)

Transmission and Drivetrain (11%)

Brakes and Traction Control (6%)

Suspension and Steering (9%)

Electrical and Air Conditioning (28%)

Paint, Rust, Leaks, Rattles, and Trim (13%)

Other (7%)

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Chart based on 2172 repairs.
See TSBs and recalls for the Ford Fusion.

Ford Fusion body repair cost distribution

$2500+ (0%)

$1000 - $2499 (1%)

$500 - $999 (4%)

$100 - $499 (15%)

< $100 (80%)

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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 

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2019 Ford Fusion 4dr Sedan

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

31620 mi Rattle in driver's door. Dealer adjusted strike plate position. Rattle gone! 

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2019 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

17000 mi Rattle and squeak from what I thought was somewhere along the rear deck. It started when the temps dropped 

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2017 Ford Fusion 4dr Sedan

turbocharged 325hp 2.7L V6 6-speed shiftable automatic AWD

21000 mi Rattle on driver door and rattle on overhead light console. Dealer could not replicate them. 
29000 mi Dealer tried to fix rattle in driver door. They broke another trim piece in the process and have ordered that to be replaced. 

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2017 Ford Fusion 4dr Sedan

turbocharged 245hp 2.0L I4 6-speed shiftable automatic FWD

8000 mi Sunglass holder would not stay closed. Dealer replaced it. 
30000 mi Dash replaced due to improper fit. 
14000 mi Sunroof leaked 

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2017 Ford Fusion 4dr Sedan

turbocharged 181hp 1.5L I4 6-speed shiftable automatic FWD

7529 mi

US $44
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. 

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2016 Ford Fusion 4dr Sedan

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

18600 mi broken door trim 
24800 mi material on steering wheel was breaking down and falling off in small pieces. replaced. moon roof warped, replaced. 
25000 mi The plastic trim around the door handles pulls up when the door is pulled shut. It does not come completely off the handle, but it moves. 
14880 mi warranty work to repaint rear bumper trim 
4960 mi Windshield was replaced due to few waves/defects in windshield, ordered and replaced at the dealer by outside glass shop. New one perfect.. 

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2016 Ford Fusion 4dr Sedan

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

250000 mi Passenger seatbelt squeeking. Attempted to lube, but didn't work, ordered new seatbelt. 

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2016 Ford Fusion 4dr Sedan

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

33000 mi 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. 

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2015 Ford Fusion 4dr Sedan

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

49000 mi

US $500
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. 

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2015 Ford Fusion 4dr Sedan

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

13000 mi 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... 

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2015 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

16700 mi Driver's seat track squeeked 
44000 mi

US $811
Drove through a puddle, underbody plastic "shield" pulled away. Part replaced, very expensive. 

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2014 Ford Fusion 4dr Sedan

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

10000 mi 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. 

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2014 Ford Fusion 4dr Sedan

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

9000 mi Banging noise coming from rear deck / trunk over certain bumps. Trunk torsion bars were banging against metal. Dealer added padding to prevent noise. 
19700 mi rattle when going over pothole. Amp loose in mounting bracket in trunk. 

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2014 Ford Fusion 4dr Sedan

turbocharged 178hp 1.6L I4 6-speed manual FWD

28000 mi Wire clip was loose in headliner, producing rattling noise. Fix covered under warranty. 

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2014 Ford Fusion 4dr Sedan

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

1000 mi Had a piece of interior trim replaced for an injection molding visual defect (splay). 
9000 mi Bezel to drivers side exterior door handle fell of car. Needed replacement piece. 
1200 mi The right interior grab handle was defective from the factory and was replaced under warranty. 

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2014 Ford Fusion 4dr Sedan

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

5100 mi 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. 

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2014 Ford Fusion 4dr Sedan

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

3000 mi Sunroof wind noise. Dealer adjusted the sunroof. Repair was covered under warranty. 
5300 mi Black piano trim around window switches on both rear doors were bowing up. 
3500 mi Replaced grab handle above front passenger door. Spring had snapped out and could not be reseated. 
12000 mi Trim between windows on drivers door kept popping out, causing wind noise. Replaced driver and passenger trim. 

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2014 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

51000 mi Door interior handle and seat belt recalls done 

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2013 Ford Fusion 4dr Sedan

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

3000 mi 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. 

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2013 Ford Fusion 4dr Sedan

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

36000 mi

US $600
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 
44790 mi

US $147
Cleaned sunroof drains to eliminate leak 
4000 mi Paint peeling on front bumper. 
54994 mi

C $1500
Fog light broken by rock, shop replaced light 

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2013 Ford Fusion 4dr Sedan

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

30000 mi 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. 

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2013 Ford Fusion 4dr Sedan

turbocharged 178hp 1.6L I4 6-speed manual FWD

6500 mi sunglass holder clip broke, trunk lid not alligned, door chrome moulding loose, all 4 tire sidewall crack (dry rot), 
34000 mi Both front door seams paint bubbled. Rust formed. Warranty claim denied. Fixed by owner. 

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2013 Ford Fusion 4dr Sedan

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

25700 mi 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. 
9000 mi Pillar was welded 

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2013 Ford Fusion 4dr Sedan

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

16000 mi 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 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

3000 mi 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 
30000 mi trunk squeaks when opening or closing 

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2012 Ford Fusion 4dr Sedan

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

8680 mi Steering column cover broken 
9380 mi Steering column cover replaced 
20200 mi sunroof was rattling, headliner was adjusted 
7440 mi Trim around rear speaker came loose. Could not repair. Had to re-book for parts to be ordered and repair to be done 

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2012 Ford Fusion 4dr Sedan

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

4000 mi 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. 
8800 mi Windshield was defective from factory. 

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2012 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

24000 mi Center console AC vents replaced. 
38200 mi

US $225
Inside door latch replaced. 
46000 mi

US $50
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 

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2011 Ford Fusion 4dr Sedan

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

11360 mi 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. 

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2011 Ford Fusion 4dr Sedan

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

14000 mi Rear windshield rubber moulding falling off. Repaired by resealing. 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

49000 mi

US $200
Door trim mounts broke. Had to replace 
37000 mi Rear window weather seal falling off again 
37800 mi rear window trim 
16100 mi sunvisor clips loose 
58000 mi Wheel nuts all rusted and do not fit socket. All 20 replaced with after market nuts. Ford charges $16 for each nut times 20. 
61400 mi

US $42
Interior door handle 

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2010 Ford Fusion

Engine not specified

9000 mi leak in sunroof diagnosed and repaired. 

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2010 Ford Fusion 4dr Sedan

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

21000 mi 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. 

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2010 Ford Fusion 4dr Sedan

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

15300 mi 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. 

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2010 Ford Fusion 4dr Sedan

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

33000 mi Sunroof leak - dealer replaced glass at no charge. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

30000 mi grab handle passenger side replaced 
89000 mi

US $207
interior driver and passenger door handles broke 
5000 mi 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. 
10000 mi Drivers inside door handle broke. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

2000 mi scratch on fender 
70500 mi

US $50
Driver's door handle broke 
34000 mi Dashboard cargo cover misaligned Trunk not centered on body. Functions fine but appears off center. Came this way from factory. 
148000 mi

US $36
Driver side interior door handle replaced... 
74100 mi Alloy wheels had corroded so tires had slow leaks. 
59000 mi

US $100
Center console storage button broken - entire center module had to be replaced. 
126480 mi

C $58
door handle on driver side door, 2nd time. Dealer cost $200. did the repair myself for the cost of the part ($58). 
29000 mi Interior door latch handle on drivers door broke/deformed 
32000 mi

US $50
Tires leaked - dealer unmounted tires and cleaned up corrosion on wheel/tire bead interface 
17360 mi Replaced chrome grille. Chrome was bubbled on two grill cross bars. 
18600 mi Top bar of chrome grill developed a "bubble" approximately 3 inches wide. The entire grill was replaced under warranty. 
13000 mi Dashboard had air bubbles in it. Dealer replaced entire dash. 
27000 mi The rubber strip at the bottom of the window kept failing off and the glue did not stick well and was always getting on things. 
136000 mi

US $50
Broken driver side door handle 

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2010 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

1000 mi 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. 

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2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

40000 mi

US $262
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 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

13000 mi Rattle in Dash and Rattle by sunroof in headliner Visor Clip Replaced, Rattle in dash was fixed. 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

150300 mi

US $100
Engine (underside) splash cover had torn loose. 
20140 mi Dash storage door hinge failure Fixed dash 
58000 mi

US $53
moonroof inoperative causing very small water leak and air noise. replaced moonroof motor, rail, and one bolt & washer. 
43000 mi

US $250
Replace broken interior door latch 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

110000 mi

US $600
Dash airbag cover re-glued 
92000 mi

US $45
door handle on dr. side broke 
3000 mi 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. 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

22940 mi 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. 
29000 mi Leather on driver's seat cracked and split open 
16700 mi warped cowl 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

51000 mi

US $200
Sunroof wouldn't 'seat' properly when closed. Determined that the frame was cracked. Replaced no charge under extended warranty 
74400 mi

US $45
The driver door handle cracked at approximately 74,000 miles and was replaced shortly after. Very simple D.I.Y. job in my opinion. 
97000 mi

US $15
Radio antenna had rusted through and broken off. Replaced antenna. 
11000 mi The center pieces of the Sport Appearance Package wheels were oxidizing. They were replaced. 
28000 mi Replaced a slightly corroded hubcap. 
45600 mi

US $100
Driver interior door handle broke, apparently a some what common problem. Bought a replacement off amazon and fixed myself 
36500 mi

US $180
driver door inside handle - mechanism broke (spring-like break inside door). Dealer would not cover repair, just outside 36,000 mile warranty. 
36300 mi Sunroof failure 
5580 mi Shop damaged B-pillar cover when removing seat. New appointment in January to replace pillar cover. 
27280 mi Driver's side external window trim peeling away at top of window. 
27400 mi Drivers side front seat, left side upright cushion side bolster disintegrated at seam, was replaced. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

64000 mi

US $45
Inside drivers door handle broken. 
111700 mi

US $700
condensation drains for moon roof were clogged with dust and tree pollin. 
293100 mi

US $10
Headliner separated and began sagging in the rear of the car. Repaired with a hot glue gun. 
28560 mi Vibration or buzzing noise coming from the engine compartment or instrument. The symptom and repair was describe in TSB 07-17-5. 
42500 mi

US $65
Broken interior door handle. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

104160 mi 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. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

63860 mi

C $2400
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 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

33000 mi  
34000 mi 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. 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

127000 mi

US $750
Rust hole is rocker panel 
44000 mi

US $100
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. 
44000 mi seat torn fixed 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

32000 mi 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!!! 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

90000 mi

US $45
Driver inside door handle broke 
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. 
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. 

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2006 Ford Fusion 4-door

6-cylinder automatic 2WD

15000 mi Door rattle. Rusted panel above license plate. 

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2006 Ford Fusion 4-door

4-cylinder manual 2WD

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.

Ford Fusion Body Problems

See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. To see how frequently Ford Fusion problems occur, check out our car reliability stats.