Ford Fusion Ford Fusion

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Ford Fusion repairs by problem area

Engine (25%)

Transmission and Drivetrain (12%)

Brakes and Traction Control (4%)

Suspension and Steering (8%)

Electrical and Air Conditioning (28%)

Paint, Rust, Leaks, Rattles, and Trim (14%)

Other (8%)

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Chart based on 1808 repairs.
See TSBs and recalls for the Ford Fusion.

Ford Fusion brake repair cost distribution

$2500+ (0%)

$1000 - $2499 (11%)

$500 - $999 (18%)

$100 - $499 (32%)

< $100 (39%)

Chart based on 74 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2013 Ford Fusion 4dr Sedan

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

16000 mi Clicking again this time resolved by chauffeuring the pads and re greasing slider pins. 
27000 mi Calipers sticking and replaced 

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2013 Ford Fusion 4dr Sedan

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

15000 mi Car self-diagnostic indicated brake system issue, very likely related to an unknown issue before I took ownership that had already been resolved. 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

36000 mi Brake ABS system...subframe chaffed harness 
36000 mi Parking brake light comes on randomly while driving. 
39000 mi Parking brake light comes on randomly while driving. Shop could not duplicate 

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2012 Ford Fusion 4dr Sedan

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

31600 mi

C $600
Severe brake fade. Total brake loss. Dealer could not duplicate. I took the car home and found my rear calipers siezed and the pads failed. I replaced all pads/rotors/calipers myself and the problem was resolved. 

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2011 Ford Fusion 4dr Sedan

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

1000 mi They replaced one wheel sensor and ABS module. 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

57000 mi

US $75
Rear brake caliper was sticking. 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

2000 mi Car computer display reported AdvanceTrac needed service. Dealer diagnosed control module needed to be replaced but did not have it in stock. Dealer ordered it for next day repair. AdvanceTrac module was successfully replaced. New car so covered under warranty. 
25000 mi Electronic stability control (Advancetrac) warning light and warning message was intermittently coming on and turning off at low and high speeds, dealer was unable to replicate problem. Problem has not occurred in the month afterwards. 
56000 mi

US $200
Front and rear brakes 
105000 mi

US $1500
Replaced front brake pads 

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2011 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

99200 mi

C $700
rear brake pad replacement and front brake cleaning 

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2010 Ford Fusion 4dr Sedan

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

29000 mi Battery would not hold charge (replaced) and stablilty control module also replaced (worked fine until battery died - don't know which caused which) 
27800 mi Owner observed unusual situation with brakes where when brakes applied, coming to stop moving forward then put in reverse, moving then applying brake a noise occurred. I described it to the dealer as a loose caliper- they may have tightened 
88600 mi

US $1000
Rear caliper guide pins had corroded causing the pads not to release and drag against the rotor causing extreme premature wear. Had to replace rotors and pads again. 

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2010 Ford Fusion 4dr Sedan

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

15300 mi Replaced leaking master cylinder cap. 

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2010 Ford Fusion 4dr Sedan

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

32000 mi

US $290
Parking brake lever was stuck in the engaged position. It was determined that the release button/cable was at fault. The entire mechanism is one unit so the whole thing had to be replaced. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

32000 mi

US $180
Car was in for routine maintenance. Mechanic noticed right rear brake pad was almost completely worn out. The suspected cause was the caliper was not sliding freely. the slides were lubricated on reassembly. Unusual problem for only 32K. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

98860 mi

C $300
Front brakes rotors and seized calipers. 
105400 mi

C $500
Replaced front and back pads and rotors. Freed stuck calibers. 
8680 mi The pistons in caliper of rear wheels don't retreat back to their original position after brake being applied. This resulted in wheels being seized if car park in hot(30 minutes) and wet(over night,rusted together) weather. 
5200 mi I had the service light go off for the traction control. It did not stay on for long, but I took it in for them to look at. They saw the alert on their computer but did not see a problem. 
30000 mi

US $156
Noted a smell of burning brakes while driving. Rear-left caliper was locked. Took to mechanic, found both rear pads shot-replaced both. Nothing wrong could be found with the calipers; suspect the parking brake froze during cold weather. 
19780 mi back passenger caliper became stuck and needed replacement along with pads and rotor. 
89000 mi

US $320
left rear pads wore out in one year, replaced defective caliper and installed new rotors 
130000 mi Front and rear rotors and pads. Rear pads were shot. 
145000 mi

US $150
Replaced rear rotors ,calipers and brakes 
122000 mi

US $1200
Rear brake pad was hung up causing wear. Declined this repair because i only want my own mechanic to do brake work. THESE SMALL PADS are a ripoff. Thanks Ford. My mech had to use special tools to remove the frozen damaged lug nuts that Bevis/But-head did to my car. Dealership said damage was due to old age of lug nuts.!!!!!!!!!!!!! Talked to customer service rep in Detroit. Would have most likely had to be towed at great expense had i found out about this on the road. 
93000 mi

US $1100
Out of Town: Brakes spongy suddenly with no warning. Dash lit up like Christmas tree. Brakes pushed to the floor and slowed to a gradual stop. In residential area, 20 mph. Can't imagine if on the hwy. Intermittent issue. Solenoid and brake replaced. in a residential area (THANK GOD) the brakes gave out AGAIN, Identical issues, Identical light show on my dash. Apparently as the solenoid and brake booster went out, they were wearing out the ABS module. Now the ABS module went kaput. 
68000 mi Pads, rotors, calipers 
84000 mi

US $130
warning light on brake air pressure 
154360 mi

C $637
front and rear brake pads rotars calipers 

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2010 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

9800 mi Sync system health-reported brake malfunction (unspecified). ABS code. Dealer had to reflash computer, no malfunction (stored code went active-unknown reason) 
73000 mi One Saturday, my wife started the car and got a zillion lights: Check engine, ABS failure, Advanctrac failure, and others. No brakes at all, pedal went all the way to the floor. I went there (20 miles) to investigate, discovered low brake fluid, and added some. With this we were able to limp it home slowly to the dealer. Brakes were unreliable, but the pedal would pump up enough to stop the car. Monday morning the dealer called to say the ABS unit was bad, and possibly another module but they'd need to replace the ABS module to be able to tell. Diagnostics showed 8-10 trouble codes including fatal failure of the ABS module. Luckily, our warranty still had about 2 weeks left, so it was covered. The other suspected module (HCU??) tested OK once the ABS was replaced. Shop time was 2-1/2 days. 
25000 mi Factory recommended re-flash for re-generative brakes 
70000 mi

US $300
During maintenance, it was determined that brake pads had to be replaced. 
6700 mi Hybrid Regenerating Brakes software flash 

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2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

28000 mi

US $270
Brake caliper froze and needed to be sandblasted, greased, and new pads installed. $270 for a rear brake job on car with under 28,000 miles. 
91500 mi

US $300
Second time our brake calipers have had issues due to corrosion. Bead blasting and all new brake seals are a pain to deal with once, let alone twice. 
97000 mi

US $936
Brake fluid was leaking from the master cylinder and there was a leak in the power steering pressurize line. Replaced the master cylinder & power steering line. 
90000 mi

US $30
Brake interlock switch broke preventing shifting out of park. I replaced the switch 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

17000 mi front brakes made a click or pop noise once when cold when backing out of the garage, Clips were installed to eliminate the noise. 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

53000 mi

US $500
Caliper froze. Caused pads and rotor damage, had to replace all. 
11000 mi Car makes metallic clunk noise occasionally when switching from D to R or R to D and then applying brakes. Issue was fixed at dealer but then came back. Still not fixed. 

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2008 Ford Fusion

Engine not specified

102000 mi Brakes gradually stopped working, Fluid was leaking, And needed to be replaced 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

89680 mi

C $500
front right caliper and rear left caliper were changed in Canadian Tire store for 500$. The problem was premature end of life of pads because the caliper was frozen. The warranty on pads and disk was used 
13000 mi Brake caliper :snapping on the disk when brake is applied . 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

81000 mi

US $10
Daughter reported soft brake pedal. After application of ABS (hard braking) pedal would be very soft and brake performance was poor. Did complete brake fluid flush by manual bleeding which solved problem. Amazing improvement. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

87000 mi

US $900
Rear brake replacement 
54000 mi

US $604
All new brake pads & rotors, balky (sticking) LR caliper freed up. Even 3,000 miles later, car stops like brand new. Gas mileage went up 2 mpg city with LR caliper fixed. 
75500 mi

US $1989
In mid-Nov.'14 my brake pedal nearly went to the floor as the ABS kicked in. It didn't recover until the next day, then it was fine for 6 weeks. On 1-3-15 it happened again & stayed that way. Dealer replaced master cylinder & HCU. 
70000 mi

US $461
Left-rear brake caliper had seized, causing those pads to drag & make the whole assembly hot. A garage had freed it up in Spring 2014 but it obviously only lasted a year-and-a-half. A local Ford dealer replaced the caliper this time. 
94240 mi

C $400
Back brakes 
107000 mi

US $330
Parking brake sticking on rear passenger wheel. Cleaned hardware and replaced rotors and pads. Problem solved. 
135500 mi

US $800
Braking ability diminished, ABS hydraulic and control module replaced. 
52200 mi

US $175
Rattle from both rear calipers. Both rear calipers were loose. Replaced mounting hardware and remounted calipers. 
58000 mi

US $800
Replaced front rotors for 2nd time, front brake pads and 4 new tires. 
60000 mi

US $150
Had to replace rear caliper hardware again. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

99800 mi

US $75
Replaced caliper carriers, front, both. Caliper pins frozen and no longer allowed calipers to move back and forth. 
118000 mi

US $1000
Replace both rear calipers. Brakes were repaired recently but calipers were problematic and should have been done earlier. 
119000 mi

US $800
Full brake rebuild - new pads, rotors and replaced all four calipers with rebuilt units because the OE calipers were "sticky" from accumulated corrosion. 
282000 mi

US $381
Driver's side rear brake caliper replaced. Brake pads replaced same visit. Driver's side rear brake caliper replaced. Brake pads replaced same visit. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

67900 mi

US $250
Left rear caliper sticking. Replaced along with wear items (pads and rotors). 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

61380 mi

C $365
Driver side rear caliper was sticking 
111000 mi

US $350
Frozen parking brake cable. Needed replacement. 
133000 mi

US $100
brake rotors, pads,  park brake adjustment. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

89000 mi One of the brake pads was rattling on the rotor. Removed the brake pad and sanded it down so it was even then reinstalled. 
102800 mi

US $10
Replaced Slide Pin Bushings on Rear Caliper slide pins due to swelling causing excessive brake drag. 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

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. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

167000 mi

US $680
Brake reservoir. Didn't fix problem now dealer wants 1100.00 to replace abs valve. 
95480 mi

C $1000
Pads, rotors, calipers, front and rear 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

97000 mi

US $400
Valve assembly. 
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. 
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. 

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Ford Fusion Brake Problems

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