2006 Ford Fusion Ford Fusion 2006

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2006 Ford Fusion repairs by problem area

Engine (28%)

Transmission and Drivetrain (11%)

Brakes and Traction Control (2%)

Suspension and Steering (10%)

Electrical and Air Conditioning (19%)

Paint, Rust, Leaks, Rattles, and Trim (20%)

Other (9%)

Chart based on 232 repairs.
See TSBs and recalls for the 2006 Ford Fusion.

2006 Ford Fusion engine repair cost distribution

$2500+ (10%)

$1000 - $2499 (2%)

$500 - $999 (6%)

$100 - $499 (56%)

< $100 (27%)

Chart based on 63 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

131400 mi

US $800
One of the injectors misfired in the rear set and had to be replaced. 
80000 mi

US $79
Replace top pulley and main serpentine belt 
165000 mi

US $145
Alternator died, oil leaking on it from sensor seal on valve cover 
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. 
81460 mi

C $270
Front engine seal was replaced, along with serpentine drive belt 
175000 mi

US $340
Ignition coils replaced. 
3000.0 mi re-torqued the top end. 
166400 mi

US $3000
Computer went out and caused 3 coils to go out. 
102300 mi

C $200
air sensor to the carb was not functioning and effected starting the car 
34000.0 mi

US $175
Replaced throttle body. 
1000.0 mi Computer reflash for transmission shifting issues. 
3100 mi Reflash PCM High idle speed at start up. No cost under warranty. 
126300 mi

US $420
Tensioner locked up destroying belt 
135000 mi

US $105
Had to refresh the pcm due to hard start issue. 
16000 mi A faulty transmission control module caused intermittent stalling and various drivability problems. 
28000 mi "Ticking" noise heard from engine within first 15 min. of driving or until engine reaches normal operating temp. 
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. 
30000 mi ticking sound from engine after warmup was bothersome. The dealer did not find anything unusual. 
97000 mi

US $230
Replace rear engine mount 
116560 mi

C $2600
Overheated ignition coils, required computer replacement as per TSB. 
5000 mi TSB for throttle response and transmission shifting issues. 
64000 mi

US $135
It was the thermostat. It failed to work. 
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. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

94240 mi

C $200
Intake gasket 
99000 mi

US $500
thermostat stuck in on position 
142000 mi

US $2800
Catalytic converter 
134500 mi

US $5100
Piston rod bearing spun 
50000.0 mi

US $1000
Bad plug coils 
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. 
69000 mi

US $160
Accessory belt and belt tensioner replaced after tensioner began squealing regularly 
74000 mi

US $328
Thermostat stuck open. After diagnostic, problem confirmed. Thermostat and housing replaced. 
72500 mi

US $430
Replaced an engine sensor (and spark plug) due to a check engine light. 
58300 mi

US $200
cooling, thermostant out 
64000 mi

US $16
oil filter cover broke , replaced my self 
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. 
96000 mi

US $120
Thermostat. Vehicle has had on and off problems with running too cold. P0128. 
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. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

25000 mi Check engine light came on, problem was thermostat stuck open 
63300 mi

US $180
Leaking valve cover gasket replaced. 
130000 mi MAF code, check engine light 
172000 mi

US $500
Replaced thermostat to clear P0128 Code. 
197000 mi

US $3500
o2 sensors 
35000 mi Transmission "reflashed" due to "late shift" from 1st to 2nd gear upon startup when vehicle sat for more than 5 hours. 
83000 mi

US $450
Thermostat change, oil change, tire rotation 
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! 
115940 mi

C $350
valve cover gasket replaced 
39000 mi

US $285
Replaced canister vent valve assembly. 
101000 mi

US $500
Air pump valve replaced 
126300 mi

US $465
Key would not come out of ignition. Replaced cylinder and lock 
135000 mi

US $275
belt idle pulley became noisy. Replaced pulley and belt 
163400 mi

US $441
Replaced thermostat 
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.  
54000.0 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). 
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!! 
91000 mi

US $235
belt tension er 
74000 mi

US $400
check engine light on, an emissions valve was bad, expensive small part at $300 
97000 mi

US $400
Oxygen sensor. 
111000 mi Spring loaded idler pulley needed to be replaced. Replaced belt while at it. 
20000 mi Gas intake problem. 
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). 
63000 mi

US $250
Check engine light indicated electronic thermostat was faulty. Replaced thermostat. Also changed front disc brake pads. 

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See TrueDelta's information for all Ford models.

2006 Ford Fusion Engine 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 2006 Ford Fusion problems occur, check out our car reliability stats.