2009 Ford Fusion Ford Fusion 2009

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2009 Ford Fusion repairs by problem area

Engine (24%)

Transmission and Drivetrain (4%)

Brakes and Traction Control (11%)

Suspension and Steering (11%)

Electrical and Air Conditioning (22%)

Paint, Rust, Leaks, Rattles, and Trim (15%)

Other (13%)

Chart based on 72 repairs.
See TSBs and recalls for the 2009 Ford Fusion.

2009 Ford Fusion repair cost distribution

$2500+ (0%)

$1000 - $2499 (4%)

$500 - $999 (9%)

$100 - $499 (38%)

< $100 (49%)

Worried about potential repair costs? An extended warranty can provide peace of mind.

Chart based on 55 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

Ford Fusion in Illinois, United States
Jan 2010 - Sep 2018
Dec 2012

36000 mi
Driver door handle internal mechanism plastic broke. Opening door requires pulling both levers to open door. The shorter handle is always stuck out and door won't lock so is always openable. At least alarm system is set with key fob. 
May 2013

40000 mi

US $262
Replace door lock mechanism and handle. Replaced driver door lock mechanism and lever which were broken. 
Jun 2017

87000 mi

US $108
mid pipe in exhaust system replaced. 
Sep 2018

99000 mi

US $332
Replace corroded transmission cooler because car suddenly was leaking fluid, mostly drops, sometimes small puddle. 
Ford Fusion in New Mexico, United States
Jul 2010 - Sep 2016
Dec 2012

76000 mi

US $6
COOLING SYSTEM BYPASS TUBE LEAKING COOLANT FROM O-RING. REPLACED O-RING 
Dec 2013

95000 mi

US $125
Thermostat bypass plastic piece leaking antifreeze when cold 
Ford Fusion in New York, United States
Oct 2010 - Oct 2012
Mar 2011

32000 mi
radio sync trouble plagued seek gets stuck on sat and getting a blip in signal playing as if I hit an overpass which interrupts signal. Phone syncing up hit or miss po'ed. Not getting the right answers from the dealer. 
Ford Fusion in Ontario, Canada
Apr 2009 - Nov 2014
Jun 2012

16120 mi

C $140
dead battery, 
Jan 2014

C $250
Ignition key would not work. Had to replace transceiver. Update: I have been away for 6 weeks since repair, car started okay when I got back. Now 2 days later it started acting up again. 
Ford Fusion in Ohio, United States
Mar 2009 - Apr 2018
Mar 2011

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. 
Jun 2011

29000 mi
Trunk lid strut replacement. Strut blown causing trunk lid to slam closed (narrowly missing hands and heads) and making trunk difficult to open. 
Aug 2011

32000 mi
Paint bubbling on rear decklid immediately beneath chrome trim. Body shop sanding, priming and repainting under warranty. 
Sep 2012

42000 mi

US $128
Replaced dead battery 
May 2013

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... 
Jun 2014

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 
Sep 2015

74000 mi

US $130
Replaced bad trunklid strut Right side foglamp assembly replacement - internal reflector faulty so fog lamp was replaced in its entirety. 
Oct 2016

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. 
Jun 2017

100023 mi

US $140
Broken inside driver's door handle/release. Part replaced. 
Apr 2018

106000 mi

US $600
Tie rod ends replaced  and sub-frame bushing replaced. 
Ford Fusion in Ontario, Canada
Sep 2008 - Nov 2015
Mar 2014

87420 mi

C $500
Radiator hose cracked from cold stress. Unfortunately the temperature dropped below -30 for more than one night. 
Ford Fusion in Michigan, United States
Jan 2009 - Sep 2015
Jan 2012

37000 mi

US $55
HVAC blower motor emitted high pitched squeaking noise; I replaced it myself. 
Ford Fusion in Louisiana, United States
Mar 2009 - Jun 2018
Jul 2009

3000 mi
car drifts to right engine has knock at idle some of the time. It is getting worse as I drive further. 
Mar 2010

7000 mi
knock comes and goes 
Sep 2010

12000 mi
horn blew on right side of steering wheel but not on left side. 
Jan 2012

48000 mi
Gas Struts for trunk lid support failed and were replaced. 
Ford Fusion in Texas, United States
May 2014 - Jun 2014
Jun 2014

89000 mi

US $500
coil on plug 
Ford Fusion in Wisconsin, United States
Sep 2009 - Jun 2016
Sep 2014

130000 mi

US $200
Left front wheel bearing required replacement. 
Ford Fusion in Pennsylvania, United States
Jun 2010 - Jun 2014
Feb 2010

1500 mi
A large part fell off of the engine onto the highway. I took the car and the part back to the dealer. They reinstalled the part at no cost. 
Ford Fusion in Minnesota, United States
Jun 2015 - Mar 2016
Jan 2016

US $30
Brake interlock switch broke preventing shifting out of park. I replaced the switch 
Ford Fusion in Minnesota, United States
Mar 2015 - Jun 2018
Dec 2015

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. 

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2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

Ford Fusion in Oregon, United States
Nov 2015 - Jan 2017
Aug 2016

97000 mi

US $1800
Car was leaking gear oil. A gear inside the differential (located inside the transaxle) was coming apart and metal shavings were very thick on the drain plug. The dealer ordered and replaced the differential with a re-manufactured one. 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

Ford Fusion in Kansas, United States
Feb 2009 - Aug 2010
Feb 2010

13000 mi
backlight out on radio button, Replaced Radio. Rattle in Dash and Rattle by sunroof in headliner The radio that was installed to fix the backlight problem had bad reception. A new radio was ordered. Visor Clip Replaced, Rattle in dash was fixed. Ordered radio was installed. 
May 2010

17000 mi
Coolant bottle would overflow when the A/C was run and the engine got hot. It was determined the cap was not sealing properly, the Coolant bottle was replaced. front brakes made a click or pop noise once when cold when backing out of the garage, Clips were installed to eliminate the noise. 
Jul 2010

18000 mi
I could feel engine vibration through the clutch pedal. The shop updated the PCM Software. Did not make a change in the vibration 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

Ford Fusion in Ohio, United States
Oct 2016 - Dec 2016
Dec 2016

135000 mi

US $320
wheel bearings on both sides. Outer tie-rod ends both sides. New tires on rear both sides. Abs wheel sensor passenger front (still not working properly). 
Ford Fusion in Ontario, Canada
Mar 2016 - Sep 2018
Nov 2016

56480 mi

C $215
replaced both rear stabilizer bar end links 
Ford Fusion in Ontario, Canada
Aug 2017 - Mar 2018
Mar 2018

194060 mi

C $375
Replaced pads and rotors. Parts supplied. 
Ford Fusion in Missouri, United States
Nov 2008 - Mar 2018
Aug 2017

43000 mi

US $250
Replace broken interior door latch 
Ford Fusion in California, United States
Apr 2009 - May 2010
Jul 2009

10000 mi
Engine threw a connecting rod, catastrophic failure - engine block destroyed 
Sep 2009

16000 mi
transmission shifting poorly and leaking fluid...pan will be resealed and OSS must be replaced. 
May 2010

24000 mi
Vehicle was repurchased by the manufacturer as a Lemon - no longer own 
Ford Fusion in Ohio, United States
Jun 2009 - Oct 2015
Apr 2011

29000 mi
transmission light came on for a few minutes. Dealership replaced a sensor. 
Jan 2014

59700 mi

US $500
Caliper froze. Caused pads and rotor damage, had to replace all. 
Ford Fusion in California, United States
Feb 2009 - Jun 2018
Jul 2010

10500 mi
Clunking sound in the front passenger door. The speaker replaced. 
Ford Fusion in Massachusetts, United States
Apr 2015 - Jun 2018
May 2015

150300 mi

US $100
Engine (underside) splash cover had torn loose. 
Oct 2015

152300 mi

US $60
Driver's inside door handle mechanism failed and had to be replaced. 
Dec 2015

154000 mi

US $21
Climate panel was failing: the temperature control knob produced weird results (cold-warm-cold-hot). I replaced the climate control panel with a part from ebay. 
Mar 2016

155000 mi

US $216
Bolt on upper control arm (passenger side) came loose and resulted in clunking sounds. Mechanic tightened it and checked all suspension bolts. 
Ford Fusion in Texas, United States
Jul 2010 - Jun 2011
Aug 2010

45900 mi

US $422
Speedometer broke. Speedo partially inoperative, operates at random/erratic times, transmission has erratic shift pattern. EEC Test, code P0720, tested and replaced OSS (Odometer Speed Sensor). Part cost = 101.82, Labor cost = 311.81. Speedometer broke. Speedo partially inoperative, operates at random/erratic times, transmission has erratic shift pattern. EEC Test, code P0720, tested and replaced OSS (Odometer Speed Sensor). Part cost = 101.82, Labor cost = 311.81 
Ford Fusion in Pennsylvania, United States
Mar 2011 - Dec 2016
Dec 2011

58000 mi

US $53
moonroof inoperative causing very small water leak and air noise. replaced moonroof motor, rail, and one bolt & washer. 
Jun 2013

80000 mi

US $90
Replaced battery 
May 2014

92000 mi

US $65
The check engine light came on with a code for the secondary air injection (emissions related). Also, the vehicle would stall on rare occasion when put into gear. The diverter valve was replace and solved the problem. 
Ford Fusion in Michigan, United States
Jul 2010 - Mar 2014
May 2011

36700 mi

US $20
HVAC motor squeaked. Replaced motor with a new unit. Solved. 
Ford Fusion in Massachusetts, United States
Jul 2010 - Mar 2012
Feb 2010

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. 
Oct 2011

29000 mi
a/c compressor noise that occurred when accelerating from a stop, could not replicate. 
Ford Fusion in Ohio, United States
Nov 2009 - Mar 2012
Dec 2009

10000 mi
No heat was coming from heater/defroster. Dealer replaced a blend door actuator. 
Ford Fusion in Ontario, Canada
Jan 2009 - Mar 2018
Jul 2010

20140 mi
Dash storage door hinge failure Fixed dash 
Aug 2012

55860 mi

C $100
Weak battery under stress. Replaced to avoid problem in the winter. 
Mar 2014

83700 mi

C $500
Replace 2 front wheel bearings 
Feb 2018

143220 mi

C $1500
Replace intake gasket to stop oil leak. replace one catalytic convertor and front end of exhaust 

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2008 Ford Fusion

Engine not specified

Ford Fusion in Alabama, United States
Aug 2015 - Sep 2015
Aug 2015

99000 mi

US $100
Ac would ruin my gas mileage by >8 mpg Rpm dropped below 500 when running it and would almost stall my car out. 
Sep 2015

102000 mi
Fuel pump busted or fell off. Air conditioner was leaking out into my floor. 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

Ford Fusion in Arkansas, United States
Mar 2008 - Nov 2010
Oct 2008

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). 
Ford Fusion in West Virginia, United States
Aug 2013 - Aug 2013
Aug 2013

92000 mi

US $400
door handle on dr. side broke water pump failure 
Ford Fusion in Pennsylvania, United States
Sep 2013 - Sep 2013
Sep 2013

102000 mi
2 Rods thrown, catastrophic failure, no indicator lights, just a loud metallic sound then, BOOM. 
Ford Fusion in Missouri, United States
Jul 2015 - Jun 2018
Dec 2016

89000 mi

US $550
Transmission lines were badly corroded and were leaking. All three lines were replaced. 
May 2018

95499 mi

US $250
Shocks and struts were replaced. 
Ford Fusion in California, United States
Mar 2008 - Jun 2018
Feb 2011

21300 mi
RR door latch mechanism sticking... auto unlock worked only intermittently. Latch mechanism was replaced by dealer under original Ford warranty. Auto-dimming mirror sometimes does not dim from auto headlights to rear of car... dealer claimed it is working to spec. Do not know how it was tested; test might have been invalid, i.e. light applied up close. 
Ford Fusion in Quebec, Canada
Jan 2015 - Jul 2018
Feb 2015

75940 mi

C $800
I lost almost all transmission fluid. The indication was a burnt smell in the car. Was able to take the car to the dealer. They change tubes running from the transmission to radiator and did flushing transmission for 800$. Transmission saved 
Jun 2015

77500 mi

C $200
Oil leak change oil seal 
Feb 2017

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 
Apr 2018

96957 mi

C $100
Ajar switch in the rear (driver side) dysfunction was starting the alarm when the car was very cold so i had to refrain from opening this door during the last winter to get time to research this on the internet. The repair imply to change the whole module for around 400$. It cost me 100$ to find out that the general info on the internet was bad and i ordered the wrong switch. Only the dealer has the good information about this specific module. So for the moment, i am waiting to observe more evident trouble. It manifest only in extreme cold weather. 
Jul 2018

99200 mi

C $400
windshield washer pump was changed with the tubes and 2 water output nozzles for a total of 400$ CND 
Ford Fusion in Washington, United States
Jan 2010 - Jun 2018
Jul 2016

162700 mi

US $70
Leaking A/C required recharging. 
May 2017

176000 mi

US $750
Evaporator core was leaking, and replaced evap temp sensor as a preventive maintenance item. 
Dec 2017

184000 mi

US $725
Hydraulic Control Unit was replaced to correct low brake pedal due to stuck valves in HCU. This is a common Fusion problem. HCU cost was $600, labor was $125. 
May 2018

190000 mi

US $100
Replaced master cylinder to resolve soft brake feel and too much pedal travel. 
Ford Fusion in Idaho, United States
Jul 2009 - Jun 2016
Jan 2013

50000 mi

US $50
Replaced headlamps. 
Ford Fusion in Tennessee, United States
Feb 2009 - Jun 2017
Mar 2009

17000 mi
Very loud noise coming from the engine area. According to the dealer, they replaced a cracked air conditioning refrigerant line and the compressor, as well as the accumulator. 
Ford Fusion in New York, United States
Aug 2008 - Nov 2013
Oct 2008

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. 
Feb 2010

22000 mi
Analog clock began running between 5 and 15 minutes fast every 24 hours. Also, hour hand was falling behind and it became impossible to tell the correct time. HVAC auto climate control head unit does not start up if left overnight during cold weather. Unit resets to "Off" and also loses stored temperature setting. Unit has to be manually switched back to "on" afetr starting the car. 
Dec 2010

33000 mi
There was noise and vibration coming from the steering column at times. Dealer tightened hose connection on power steering pump and added more fluid. 
Dec 2012

55000 mi

US $150
Interior door latch for driver's door broke. Door could not be opened from the inside. 
Aug 2013

59600 mi

US $2100
Moon roof track was broken and motor contained plastic shards from the track. 
Ford Fusion in Missouri, United States
Mar 2011 - Oct 2015
Jul 2012

81500 mi

US $2000
Engine control computer replaced 
Ford Fusion in Alberta, Canada
Aug 2012 - Jun 2018
Dec 2012

48360 mi

C $1290
Repair oil leak from oil pan and engine output seal 
Jan 2018

84320 mi

C $200
Replaced coolant manifold and temperature sensor due to leak at coolant temperature sensor. 
Ford Fusion in Wisconsin, United States
Oct 2007 - Dec 2012
Apr 2009

8000 mi
Radio had popping noise.  Tire Valve stem replace. Leaky tire 
Sep 2010

20000 mi
Part described as a module or a sensor. Dash board had to be taken off. Air conditioning would not blow cold air.  
Ford Fusion in Ohio, United States
Nov 2010 - May 2011
May 2010

29000 mi
Battery cable and battery replaced under warranty due to serious corrosion at the positive battery terminal connector 
Ford Fusion in Arizona, United States
Aug 2016 - Jul 2018
Jul 2017

125000 mi

US $700
Left front wheel was making an awful clunking/howling noise and felt loose when wiggled while on a jack. Wheel bearing was replaced. Left halfshaft was replaced as well due to torn boots. 
Ford Fusion in Georgia, United States
Jan 2008 - Oct 2016
Apr 2008

2000 mi
Driver's side door panel retaining clip(s) had come unseated resulting in loose door panel and clip rolling around inside of door. 
May 2010

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. 
Jul 2010

30000 mi
Trunk shocks blew out and would not longer lift or support the trunk. Dealer replaced under warranty. 
Oct 2012

54500 mi
Valve cover gaskets reported by service tech as leaking. Replaced under 5yr/60K power-train warranty. 
Oct 2016

76000 mi
Data Link Connector for OBD computer not responding to emissions sync. Diagnosed, checked & corrected. 
Ford Fusion in New Jersey, United States
Sep 2007 - Jun 2011
Jun 2008

10000 mi
Starter "catches" sometimes when turning the key. Makes a short "zing" noise. Couldn't replicate it at the dealership nor could I in the parking lot. They were very good and told me to bring it back if it repeated. 
Ford Fusion in Ontario, Canada
Jan 2016 - Feb 2016
Jan 2016

119660 mi

C $1675
Broken engine mount 
Ford Fusion in Michigan, United States
- Nov 2008
Nov 2008

13000 mi
Brake caliper :snapping on the disk when brake is applied . 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

Ford Fusion in Illinois, United States
Jan 2012 - Dec 2016
Dec 2016

135000 mi

US $350
Leaking trans pan gasket. Replace trans pan gasket flush system, and replace filter. 
Ford Fusion in West Virginia, United States
Feb 2012 - Jun 2018
Jun 2012

60000 mi

US $30
Transmission oil cooler lines were rusted and leaking. I replaced them myself. 
Jan 2018

167000 mi

US $300
One rear brake was sticking. The caliper and pads were replaced. I had previously replaced the caliper myself, but the one I installed apparently was defective. The driver's side caliper apparently had been sticking somewhat for several years, as that wheel was often hotter than the others and the pads wore out more often. 
Ford Fusion in Manitoba, Canada
Nov 2012 - Jun 2017
Jun 2017

96100 mi

C $2000
Transfer case or Power Transfer unit, does not have a drain plug, this is not considered a serviceable part. The only way this can be changed is to remove the part and turn it upside down at 5.5hrs mechanic labour. OEM 1600-2000, wrecker $500 Driveshaft, bad ujoint, again ujoints are not replaceable and you have to buy another driveshaft. OEM 1600, aftermarket 800 Do not buy a ford AWD in the 130km and up range, you are asking for this repair! I know this is my last ford! 
Ford Fusion in Massachusetts, United States
Mar 2008 - Jun 2018
Mar 2009

20000 mi
Fuel cap needed to be replaced/caused ck engine light to go on. 
Ford Fusion in New York, United States
Mar 2008 - Sep 2010
Apr 2010

16700 mi
warped cowl 
Ford Fusion in Colorado, United States
Feb 2012 - Jan 2018
May 2012

35000 mi

US $325
One of the battery cables attaching to the battery corroded and fell off. I needed to get the Fusion towed to a repair shop. 
Ford Fusion in Pennsylvania, United States
Jan 2008 - Sep 2009
Feb 2008

1000 mi
Auto dimming mirror not working correctly, new one ordered and installed. 
Ford Fusion in Alberta, Canada
Sep 2007 - Jun 2010
Mar 2010

22940 mi
noise when window going down on drivers side, repaired with tsb for known concern. no charge to customer 
Ford Fusion in Ontario, Canada
Mar 2008 - Jun 2018
Aug 2008

4960 mi
Driver's door sill damaged during installation at factory, noticed as a white dsicoloration of camel colored door sill, part on order from US 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. 
Sep 2010

29140 mi
Moaning noise under power coming from behind driver. Diagnosed by Ford mechanic as a bad hanger bearing, drivershaft replaced, one day wait on parts. 
Jul 2012

45260 mi

C $218
Car began showing symptoms of hard/long cranking (also SRS light would not go out after car started) 
Apr 2018

85560 mi

C $1700
Noise and vibration when driving from right side of car. Dealership diagnosed as two bad right side wheel bearings (front/rear) both replaced and car returned to normal operation 
Ford Fusion in Indiana, United States
Mar 2008 - Sep 2014
Jun 2008

3000 mi
Blown passenger front speaker. Audiophile System. 
Jan 2009

14000 mi
HVAC blower motor squeaking. 
Dec 2009

29000 mi
Leather on driver's seat cracked and split open 
Dec 2010

38000 mi
Carrier bearing failed on the driveshaft (AWD). Entire driveshaft was replaced as a result. 
Jul 2013

85000 mi

US $2100
PCM failed and damaged the ignition coils and plugs requiring replacemet of all items. 
Sep 2014

105000 mi

US $150
Wheel bearings went bad on the front end. Both were replaced. 
Ford Fusion in Indiana, United States
Aug 2012 - Dec 2013
Aug 2013

76400 mi

US $829
Replaced rear driveshaft due to failed front carrier bearing. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

Ford Fusion in Ohio, United States
Sep 2007 - Jun 2011
Oct 2007

1000 mi
Fuel pump pressure bleed down overnight 
Ford Fusion in Minnesota, United States
Jul 2009 - Jun 2018
Dec 2014

74000 mi

US $120
Valve cover gasket was leaking oil. My mechanic said it wasn't major but definitely leaking. He replaced it. 
Mar 2016

92000 mi

US $770
Oil leak at timing chain cover. oil dripping on accessory belt causing it to squeal. 
Dec 2017

100000 mi

US $500
Power steering pump was leaking. Pump was replaced 
Ford Fusion in Utah, United States
Apr 2008 - Jan 2012
Oct 2009

30000 mi
Some type of oil cap was cracked, allowing oil to leak from engine compartment. 
Ford Fusion in Alberta, Canada
Sep 2010 - Jun 2012
Dec 2010

56420 mi
In the winter, the heat does not flow to the rear of the car. In fact, it actually blows cold air to the passengers in the back seat and also to the floor vent of the front passenger seat. Dealer never able to find problem. 
Dec 2011

77500 mi
Driver's inside door handle would not work/door wld not open. Entire handle had to be replaced, take door apart to do this. (Also, Chrome on inside door handle peeling off, leaving sharp edge.) Rear Defrost stopped working after handle replaced. Dealer said coincidence. Not yet fixed. 
Mar 2012

85560 mi

C $97
Changed headlights. (It is a pain to do it on this car, so decided to take it to the dealer). Would like to see Ford make it a bit easier for the owner to access these small things. 
Ford Fusion in Minnesota, United States
Jan 2009 - Dec 2010
Feb 2009

8000 mi
One repair - to replace SYNC system master unit. Took 3 days in Feb. Unsuccessful, is likely an unresolved software issue, not hardware. 
Ford Fusion in California, United States
Sep 2010 - Aug 2011
Dec 2010

71000 mi

US $3000
Lemon car all the way around. Had been noticing problems with the transmission when first bought car and under warranty. 2,000mi out of warr and transmission blew. Ford would not honor their part. We paid...they don't care. Will never buy Ford again. 
Ford Fusion in Connecticut, United States
- Feb 2008
Feb 2008

1200 mi
Blower motor would squeak at low speeds. Found the fan bearing to be out of balance. Had to get the heater core blower fan and motor replaced. 
Ford Fusion in Ontario, Canada
Jun 2012 - Oct 2017
May 2013

52320 mi

C $250
Blown steering line - hose had rubbed through. 
Mar 2015

69440 mi

C $375
Failure of PATS security system, required new keys and reprogramming. 
Ford Fusion in Florida, United States
Jun 2015 - Jun 2015
Jun 2015

81000 mi

US $10
Temp gauge would not come up to center. Code for coolant temp out of range found (P0128?) Replaced thermostat which fixed problem. Access was difficult and not for the first-timer. 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

Ford Fusion in New Jersey, United States
Mar 2008 - Nov 2017
Jan 2014

119000 mi

US $400
Head gasket replaced 
Oct 2015

161700 mi

US $300
Valve kit replacement 
Ford Fusion in Minnesota, United States
Sep 2013 - Jun 2018
Dec 2013

28000 mi

US $262
Replaced thermostat 
Apr 2015

35000 mi

US $100
Bearing howling. small water leak CD's stuck in multi disc changr Blower motor noisy when cold 
Jul 2017

48033 mi

US $100
Timing Belt Tensioner 
Ford Fusion in British Columbia, Canada
Mar 2008 - Oct 2015
Oct 2008

4960 mi
Driver's seat makes internal rubbing sound when seatback pressed against on right side. Shop determined in-seat airbag assembly rubbing, could not resolve with standard procedures. Waiting for reply from manufacturer. 
Dec 2008

5580 mi
Cracked internal seat frame replaced. Problem reduced but not eliminated. Continue work on seat. Shop damaged B-pillar cover when removing seat. New appointment in January to replace pillar cover. 
Jan 2009

6820 mi
Dealer tried to fix seat once again and failed to do so. Ordered new foam seat core - the last original part of the seatback. Did not replace B-pillar cover as seat is expected to be removed again. Replacement of foam core of seatback finally solved the original problem. 
Feb 2011

27280 mi
Replaced noisy (ticking) HVAC blower fan. Driver's side external window trim peeling away at top of window. 
Ford Fusion in Minnesota, United States
Sep 2015 - Oct 2016
Jul 2016

136000 mi
Oil pan gasket. 
Ford Fusion in Massachusetts, United States
Apr 2008 - Mar 2012
May 2009

12000 mi
Sun Roof retraction bar snapped, causing roof to twist and remain in up-right position. Entire unit needed replacement. 
Jul 2011

36300 mi
Sunroof failure 
Ford Fusion in Massachusetts, United States
Sep 2009 - Jul 2017
Oct 2010

37000 mi

US $200
Car failed to start. jump started by AAA. Car driven to dealer who replaced the battery and tested systems. Told battery was 'Worn out" out of warranty replacement. Approx $150 out of pocket cost Clicking noise from heater fan. Parts replaced under extended warranty. $50 decuctable and rental car reimbustment. 
Nov 2011

51000 mi

US $200
Sunroof wouldn't 'seat' properly when closed. Determined that the frame was cracked. Replaced no charge under extended warranty Chirping sound from heater fan previously replaced 1 yr ago re-occured and the shop replaced the part again. 
Aug 2012

63700 mi

US $190
INTERIOR DRIVERS SIDE DOOR HANDLE MALFUNCTION 
Feb 2014

91000 mi

US $370
Check engine reveled an air intake item needed reoplacement 
Ford Fusion in Ohio, United States
Dec 2017 - Jun 2018
Jan 2018

108000 mi

US $500
Bad transmission sensor and cable 
Ford Fusion in Florida, United States
May 2016 - Jun 2018
Nov 2017

92000 mi

US $800
engine coolant replaced, radiator hoses replaced, thermostat replaced. thermostat had failed. 
Jun 2018

97000 mi

US $15
Radio antenna had rusted through and broken off. Replaced antenna. 
Ford Fusion in Indiana, United States
Feb 2010 - Jul 2013
Oct 2010

30100 mi
Battery died 2.5 years after purchase. Dealer towed car, gave me rental for weekend, and replaced battery. No charge, just inconvenienced since occurred about 20 miles from home & dealer. 
Apr 2011

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. 
Ford Fusion in Wisconsin, United States
May 2013 - Jun 2018
May 2017

116000 mi

US $50
Thermostat replaced. It was causing a check engine light. 
Ford Fusion in New York, United States
Dec 2007 - Nov 2014
May 2011

10000 mi
They adjusted or replaced some sensors 
Mar 2013

11000 mi

US $200
TPMS malfunction 
Ford Fusion in New York, United States
Jul 2016 - Apr 2017
Sep 2016

87000 mi

US $900
Rear brake replacement 
Ford Fusion in Minnesota, United States
Sep 2008 - Mar 2016
Jun 2015

93000 mi

US $145
Replace leaky valve cover gasket. 
Jan 2016

55500 mi

US $120
intake manifold gasket 
Ford Fusion in Indiana, United States
Oct 2010 - Jan 2014
Nov 2010

31000 mi
Both front door windows had vertical scratches. An Internet search led me to a TSB that addressed this problem. Ford dealer ordered parts. CEL had code read at AutoZone P2004 IMRC stuck open. Left car with dealer for a day.They acknowledged the problem but were unable to service the car that day.2 days later the CEL reset.Will wait to see if it happens again. 
Ford Fusion in Ohio, United States
Jul 2008 - Jul 2018
Mar 2014

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. Corroded spot fixed on a wheel lip causing a tire leak at the bead. 
Jan 2015

68800 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. 
Dec 2015

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. Noticed an oil burning smell inside the car when not in motion, the engine warmed up & running. No visible smoke. Dealer replaced valve cover gasket & cleaned the engine. 
Feb 2017

80000 mi

US $697
Engine light came on, I checked it & it read PO128 : a bad cooling thermostat. Car had been running cool so it was obviously stuck open. Garage changed it for $199.56 Front end squeak while turning at low speeds. Garage said tie-rod ends were bad & could be the problem, but said it''s usually ball joints even though mine were in good shape. Tie-rod ends replaced at $148.04 *note* ...The front end squeak never went away and I suspected my ball joints were very dry inside. In March I bought and used a grease needle. A ten-minute job and the car's front end is very quiet now :) 
Jul 2017

82083 mi

US $694
Replaced all brake rotors and pads plus two calipers Recharged A/C system 
Mar 2018

88000 mi

US $120
Power door lock actuator for the front passenger door failed. Bought a new one for $120 and replaced it myself. 
Jul 2018

88500 mi

US $264
Had a fluid drip - not engine coolant - under the radiator. A local repair shop found the transmission lines going to the cooler built into the radiator were leaking and replaced them. 
Ford Fusion in Pennsylvania, United States
Nov 2008 - Dec 2012
Feb 2009

8000 mi
Had PCM flashed to resolve the transmission's jerky shifting. Driver's side seat had cracks and was replaced. 
Jul 2009

11000 mi
The center pieces of the Sport Appearance Package wheels were oxidizing. They were replaced. 
Feb 2011

25500 mi
I noticed the check engine light so I took my car to a dealership. They found out it was a bad catalytic converter and it was replaced under the factory warranty. 
Jun 2011

28000 mi
Replaced a slightly corroded hubcap. 
Ford Fusion in Pennsylvania, United States
Oct 2010 - Dec 2017
May 2011

27400 mi
Drivers side front seat, left side upright cushion side bolster disintegrated at seam, was replaced. 
Nov 2014

41300 mi

US $900
Noise corresponding to road speed. Some sort of shaft bearing was bad. Also replace alternator, thought that was problem. 
Jul 2016

52200 mi

US $175
Front and rear sway bar end links worn out causing a rattle going over uneven surfaces. Rattle from both rear calipers. Both rear calipers were loose. Replaced mounting hardware and remounted calipers. 
Mar 2017

58000 mi

US $800
Replaced front rotors for 2nd time, front brake pads and 4 new tires. 
Jun 2017

60000 mi

US $150
Had to replace rear caliper hardware again. Had to reposition the the left front strut spring sadddle rubber on bottom, slid out of position. 
Ford Fusion in North Carolina, United States
Jun 2009 - Jul 2015
Oct 2013

68800 mi

US $320
Torn CV Boot 
Ford Fusion in Wisconsin, United States
Jun 2012 - Sep 2016
Aug 2013

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. 
Mar 2014

82000 mi

US $215
Replaced valve cover seals to stop minor oil leak. Replace both tie-rod ends 
Mar 2016

107000 mi

US $330
Parking brake sticking on rear passenger wheel. Cleaned hardware and replaced rotors and pads. Problem solved. 
Ford Fusion in Michigan, United States
Oct 2008 - Jun 2011
Feb 2011

30000 mi
Leak from oil pan or transmission. 
Ford Fusion in Minnesota, United States
Dec 2010 - Jun 2018
Feb 2011

32000 mi

US $500
Coil pack and all spark plugs. Coil pack and all spark plugs 
Ford Fusion in British Columbia, Canada
Aug 2009 - Jun 2018
Jun 2012

58900 mi
replace crankcase seal & coolant pump. 
Feb 2013

63840 mi

C $50
replace headlight. 
Jun 2014

71300 mi

C $400
replace thermostat 
Jun 2017

92380 mi

C $170
replace tire pressure sensor 
Jul 2017

92380 mi

C $420
Power window switch repair. 
Oct 2017

94240 mi

C $400
Back brakes 
Ford Fusion in Pennsylvania, United States
Aug 2012 - Dec 2017
Oct 2016

135500 mi

US $800
Braking ability diminished, ABS hydraulic and control module replaced. 
Ford Fusion in Manitoba, Canada
Jun 2008 - Oct 2015
Feb 2009

8060 mi
After a cold soak ( -25 C) the heater / Air Conditioner computer stays blank and looses it's memory. The heater will not work until a manual selection is made. Ford is working on the problem. A fix not available yet. 
Apr 2009

10540 mi
When cold soaked, the Air Conditioner / heater computer loses its memory and the heat will not come on when command start is used. Ford is working on a fix.  
Sep 2009

15178 mi
auto dimming mirror intermittant. replaced auto dimming mirror replaced under warranty 
Mar 2015

78740 mi

C $468
thermostat stuck 
Ford Fusion in California, United States
Apr 2011 - Dec 2016
Nov 2013

45600 mi

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

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2007 Ford Fusion

Engine not specified

Ford Fusion in Ohio, United States
May 2011 - Jun 2011
Jun 2011

109000 mi

US $750
sensor for air conditioning needed replaced. Cost $100 to evaluate. Part was $18. Entire dashboard had to be removed to replace sensor which is known to short out. 
Ford Fusion in Missouri, United States
Nov 2016 - Nov 2016
Nov 2016

US $300
Abnormal ticking. Inside valve train system. Undiagnosed. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

Ford Fusion in West Virginia, United States
Mar 2015 - Jun 2016
Jun 2015

139000 mi

US $850
Had to have the valve body replaced in the transmission 
May 2016

156400 mi

US $203
Felt as if you had taken your foot off of the throttle 
Ford Fusion in Massachusetts, United States
Feb 2010 - Mar 2013
Jul 2012

111700 mi

US $700
condensation drains for moon roof were clogged with dust and tree pollin. 
Feb 2013

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. 
Ford Fusion in Kansas, United States
Aug 2009 - Jul 2018
Jan 2013

73300 mi

US $65
Broken interior door handle. 
May 2014

85000 mi

US $753
Replaced front shocks trying to eliminate a suspension noise. Noise still present after shock replacement so greased left ball joints as best as possible (since there are no zerks) and noise went away after about a week. 
Jun 2015

96000 mi

US $200
Replaced control arms to resolve ball joint creaking noise issue 
Ford Fusion in Ontario, Canada
Dec 2006 - Nov 2014
Jan 2009

44640 mi

C $180
Service engine light, with hesitation an acceleration. 
Nov 2009

71300 mi
Heated drivers seat not working  
Jul 2010

76880 mi

C $400
Key stuck in ignition T.S.B. Drivers side heated seat not working 
Nov 2014

169880 mi

C $450
hesitates on accelleration 
Ford Fusion in Michigan, United States
Feb 2014 - Jun 2018
Aug 2015

98600 mi

US $1200
The module in the instrument cluster broken in order to get the panic button to the key fob to work had to replace cluster. 
Mar 2016

104000 mi

US $95
Radio display was not working needed soldering Dealership wanted to replace radio for $600 including labor. 
Nov 2016

110000 mi

US $175
Door lock front right door was not locking replace interior mechanism and handle and lock. 
Apr 2017

115000 mi

US $140
Brake Switch Transmission would not shift 
Dec 2017

122000 mi

US $145
Low oil pressure light came on Oil leak was fixed. 
Jun 2018

128000 mi

US $625
Right Rear Sway Bar and Right Front Tie Rod also had some door dent bumped out and rear seat work done patch job 
Ford Fusion in Illinois, United States
Mar 2010 - Jul 2018
Nov 2010

43000 mi
driver side heated seat stopped working. control does light up for about 1/2 second but then shuts off. 
Jul 2012

64700 mi

US $125
Airbag light came on and stayed on. Electrical system acting "funny". Turns out the battery failed to hold a charge and once it was replaced the airbag light stayed off and things seem normmal again. 
Apr 2015

99800 mi

US $75
Replaced caliper carriers, front, both. Caliper pins frozen and no longer allowed calipers to move back and forth. 
Feb 2016

113000 mi

US $200
replace (1) oxygen sensor replace sensor in dashboard that was preventing the AC compressor from running replace leaking transmission cooler lines that run to the radiator, Slow leak. Showed a red spot under that car when parked overnight. 
Jun 2016

118000 mi

US $1000
Replace both tie rod ends. Steering wonky. replace sway bar links - front. Making noise Replace both rear calipers. Brakes were repaired recently but calipers were problematic and should have been done earlier. 
Oct 2016

122000 mi

US $120
airbag light comes on and stays on when starting engine. engine cranking slow. Needed a jump once because battery died on a short trip. Replaced battery and all is well again. No airbag light with new battery. 
Dec 2017

151000 mi
Replaced flex joint. 
Ford Fusion in Florida, United States
Jun 2013 - Jun 2014
Jun 2013

88000 mi

US $2700
ECU burned out, leaving all 6 coils open, melting each one. Had to replace ECU and all 6 coils. 
Ford Fusion in Wisconsin, United States
Oct 2012 - Mar 2014
Mar 2014

80000 mi

US $250
Drivers side front lower control arm replaced due to noisy bushing. 
Ford Fusion in Tennessee, United States
May 2009 - Aug 2012
Jun 2009

143000 mi
Transmission replacement. 
Jul 2009

148000 mi
Power window motor, passenger side. 
Sep 2009

159000 mi
Fuel pump, car died in the middle of nowhere, outside of cell reception. Idler pulley and serpentine belt. 
Oct 2009

170000 mi
Water pump. 
Nov 2009

173500 mi
Linkage connecting driver's door handle to release mechanism snapped. 
Dec 2009

175000 mi
Window regulator, driver's door. Radio replaced due to screen burning out. 
Jan 2010

180000 mi
Transmission linkage repaired--would not shift out of drive.  
Feb 2010

186000 mi
Wheel bearings, front. 
Apr 2010

197000 mi
Wheel bearings, rear. Power steering pump and pressure hose. 
Jun 2010

206000 mi
Power Steering pressure switch failed. 
Sep 2010

227000 mi
Power seat motor failed. Replaced with junkyard part. LCD display quit working on radio about 6 months ago. Trip computer not working correctly. Resets at random. Car not worth cost of repair. 
Oct 2010

235000 mi
Water Pump failed. 
Apr 2011

270000 mi

US $12
Both front marker light sockets melted. Replaced with junkyard parts. Both front marker light sockets melted. Replaced with junkyard parts. 
May 2011

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. 
Aug 2011

288700 mi

US $101
Heater hose T-junction cracked. Heater hoses/coolant replaced during repair as well. 
Jan 2012

257500 mi

US $117
Positive battery cable separated and started arcing to the battery and nearby metallic components. 
Feb 2012

293100 mi

US $10
Headliner separated and began sagging in the rear of the car. Repaired with a hot glue gun. 
Jun 2012

296000 mi
Compressor and blower motor failed. Cost of repair exceeded vehicle's value. 
Ford Fusion in British Columbia, Canada
Feb 2009 - Apr 2011
Nov 2009

27900 mi
Vibration or buzzing noise coming from the engine compartment or instrument. The symptom and repair was describe in TSB 07-17-5. Vibration or buzzing noise coming from the engine compartment or instrument. The symptom and repair was describe in TSB 07-17-5. 
Ford Fusion in Florida, United States
Mar 2015 - Jul 2018
Dec 2015

135000 mi

US $70
Leak from plastic portion of upper radiator hose. Replaced hose. Also replaced coolant as service was due soon. 
Jan 2016

US $100
rear shocks worn out (rear end very bouncy whenever even light load present), replaced shocks 
Aug 2016

143000 mi

US $263
serpentine belt failed. replaced main serpentine belt, both idlers, and tensioner. 
Ford Fusion in California, United States
May 2008 - Sep 2014
Jan 2008

7000 mi
TSB reported repair for Audiophile rear speaker pop when brake pedal is applied. New ground for rear speakers was connected and no problems since. 
Mar 2013

64000 mi

US $45
Inside drivers door handle broken. 
Feb 2014

77900 mi

US $300
Replaced rear shocks because they were blown. They were worn out a little prematurely because the car is slightly lowered. 
Aug 2014

86000 mi

US $70
Replaced serpentine belt. 
Ford Fusion in Arizona, United States
Sep 2006 - Mar 2010
Aug 2007

13000 mi
The air conditioning fan speed is less than the amount specified by the user, and it flutters up and down in speed several times per second (never reaching full speed). The front right window makes a crackling noise (like crumpling paper) whenever it is moved to the closed position. Moonroof occasionally makes gear grinding noise when opening/closing. Could not reproduce problem during this trip. 
Sep 2007

14000 mi
The air conditioning fan speed is less than the amount specified by the user, and it flutters up and down in speed several times per second (never reaching full speed). The front right window makes a crackling noise (like crumpling paper) whenever it is moved to the closed position. I felt that the air conditioning fan speed was still reduced, even after the repair from the previous week. Dealership held car overnight, then compared its air flow to another similar car and decided that air flow level was fine. 
Ford Fusion in Michigan, United States
Jul 2011 - Apr 2018
Apr 2017

134000 mi

US $746
Squeaking when braking. Brakes and rotors previously replaced. On this repair, replaced front control arms and ball joints and front sway bar links. Leaking under front of car. Transmission Oil Cooler Line had rusted through and was replaced. 
Ford Fusion in California, United States
Oct 2008 - Dec 2013
Jul 2013

118700 mi

US $100
Tie rod bushing and axle boot ripped. Probably caused because car has been lowered for almost 100k miles 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

Ford Fusion in Idaho, United States
Feb 2007 - Mar 2010
Dec 2007

4000 mi
Car seems to hesitate when accelerating there have been TSB's for this in the past but for my particular car (2007 awd v6) one was not found and I was told all fusions do this. Also took it in for a squeeky passenger seat which they did do the TSB repair 
Ford Fusion in Maryland, United States
Nov 2006 - Mar 2010
Feb 2007

2000 mi
Terrible in-city gas mileage, 13 mpg 
Ford Fusion in Michigan, United States
Aug 2008 - Oct 2010
Feb 2009

31000 mi
A bearing went out in right rear axle. 
Ford Fusion in Ontario, Canada
Dec 2010 - Jun 2018
Oct 2014

75940 mi
muffler pipe welded back on; oil change 
Ford Fusion in New Brunswick, Canada
Apr 2013 - Jun 2018
May 2013

101360 mi
AWD car, half shaft joint went, had to replace shaft. 
Sep 2013

102920 mi

C $25
Evaporator tray sensor fried, had to replace. Cheap part, but have to remove dash to access. 
Sep 2014

109740 mi

C $200
Ball joint went, replaced entire control arm as it was easier. 
Apr 2018

148800 mi

C $500
Brakes all around Front sway bar links replaced Rear shocks replaced 
Ford Fusion in Ontario, Canada
Apr 2010 - Sep 2013
May 2010

64480 mi

C $1400
This car has been a disaster since the day i got. shaft in transfer case replaced, both front half axle shafts, balljoint, hanger bearings x 2, and 1 front wheel bearing. This is a car I have only owned since dec of 2008 not impressed ford 
Dec 2012

93620 mi

C $3900
there is a steel shaft that transfers torque with fords AWD system. this part has now been replaced # times approx every 50000km 
Ford Fusion in Ontario, Canada
Oct 2013 - Sep 2017
Feb 2017

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. Failed transfer box. 
Ford Fusion in Ontario, Canada
Nov 2010 - Jun 2013
Apr 2013

79440 mi

C $102
Battery died'stoped holding its charge 
Ford Fusion in New York, United States
Nov 2009 - Mar 2016
Feb 2011

100500 mi

US $600
Light noise while car was in motion got much louder - carrier bearing on rear driveshaft had failed due to an imbalanced driveshaft (TSB issued but wasn't fixed by prev. owner). Repair was to replace entire driveshaft assembly. 
Nov 2011

118500 mi

US $230
Squeaking and uneven tire wear caused by worn out struts. Replaced front struts and rear shocks. 
Mar 2013

140000 mi

US $1100
Failed transfer case was causing loud grinding noise. Needed replacement. 
Mar 2016

166000 mi

US $200
Right front wheel bearing 
Ford Fusion in Pennsylvania, United States
Mar 2015 - Dec 2017
May 2015

67900 mi

US $250
Left rear caliper sticking. Replaced along with wear items (pads and rotors). 
Ford Fusion in Saskatchewan, Canada
Aug 2007 - Sep 2010
Jun 2008

13640 mi
A/C stinks, dealer tried fixing 3 times, still stinks. Probably won't buy another Ford, after always owning them. 
Ford Fusion in Alberta, Canada
Dec 2009 - Sep 2015
Jan 2010

18600 mi

C $200
car 2x would not start 
Jun 2010

19220 mi

C $480
electrical problem, would not start sulfur smelle 
Jul 2013

42160 mi

C $500
Unintended acceleration. The dealer could find no problems. Electrical -running lights wouldn't turn off, locks wouldn't work. 
Mar 2014

47120 mi

C $1600
Replace wheel bearings front and rear. 
Ford Fusion in North Carolina, United States
Mar 2007 - Mar 2011
Jun 2009

50000 mi
Coudy transmission fluid. Occassional harsh shift. Per Ford TSB internal transmission component changed and PCM reprogrammed. Car was driving OK when dropped off, but the transmission fluid was very dirty. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

Ford Fusion in Michigan, United States
Sep 2015 - Dec 2017
Dec 2015

111000 mi

US $350
Frozen parking brake cable. Needed replacement. 
Sep 2016

122000 mi

US $500
rear upper control arm struts and shocks 
Jul 2017

133000 mi

US $100
brake rotors, pads,  park brake adjustment. 
Ford Fusion in Michigan, United States
May 2010 - Mar 2017
Mar 2012

71000 mi

US $62
DTC for "engine warmup time exceeds threshold" set, temp gauge reads low. Replaced thermostat. 
Sep 2012

79000 mi

US $80
Manual trans wouldn't go into gear. Trans fluid change resolved issue 
Apr 2014

103700 mi

US $260
Right front wheel bearing replaced 
Dec 2015

129000 mi

US $60
Replaced cylinder cover gasket. Did plugs while i was at it. 
Ford Fusion in Ontario, Canada
May 2010 - Sep 2017
Jan 2011

37200 mi

C $140
Difficulty shifting. The problem is mostly experienced when the car is cold and when shifting into 2nd (this is a manual transmission). 
Jun 2014

55180 mi

C $340
There were clunks when entering driveways etc. Engine light came on. Thermostat was replaced. Issue resolved. It had been running cool. 
Apr 2016

61380 mi
Speed sensor has failed consequently the speedometer and odometer are not working. Also, the engine light is on (assumed to be related since there are no other issues). It will take 2 months to get the part due to high demand. 
Sep 2016

61380 mi

C $420
Speed sensor failed in April but part didn't arrive until Sept. Part was $280 and installation was $140. No changed in odometer due to odometer not working. 
Dec 2016

61380 mi

C $365
Driver side rear caliper was sticking 
Apr 2017

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. 
Ford Fusion in Michigan, United States
Apr 2007 - Jun 2015
Feb 2008

10000 mi
Chirp through rear speakers when the brakes were applied. A known problem with the premium sound system. Repaired using instructions from TSB. 
Sep 2014

115000 mi

US $477
Replaced thermostat after obdII light issued code P028 (Engine fails to reach operating temperature in required time). 
Ford Fusion in Quebec, Canada
Aug 2007 - Aug 2011
Nov 2007

3100 mi
trimming around the door was loose 
Feb 2008

6200 mi
Prob is fixed. 
Jun 2008

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 
Jan 2009

17360 mi
Thermostat stopped working. 
Ford Fusion in Nebraska, United States
Oct 2006 - Jul 2013
Sep 2009

29000 mi
Idle 2500-3500 RPM after warm up. Shut off and restarted engine, same symptoms. Called dealer, no idea. Went back out, started car, now worked perfectly. Has not recurred in 3000 miles. 
Jun 2013

65000 mi

US $300
Left axle shaft (that turned out to not be the problem) and left front wheel bearing. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

Ford Fusion in Washington, United States
Feb 2009 - Jan 2016
Feb 2014

114000 mi

US $320
Thermostat had been stuck open for a few months. Also serpentine belt squeaking. Replaced thermostat, belt, and tensioner pulley. 
Sep 2014

126000 mi

US $120
Engine started knocking a couple months ago. Finally threw a rod. Replaced entire engine. CV boots have been cracked for about 30k miles. Finally replaced them. They were NOT making any noise. 
Jan 2016

136000 mi
Blew second engine. Vehicle sitting until summer to replace it again. 
Ford Fusion in Brazil
Nov 2008 - Apr 2010
Mar 2009

6820 mi
Suspension sounds wrong. 
Jun 2009

6820 mi
Motor mount. 
Ford Fusion in Michigan, United States
Dec 2008 - Jun 2011
Nov 2009

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. 
Ford Fusion in California, United States
Jan 2015 - Mar 2018
Dec 2015

132000 mi

US $50
Replaced belt tensioner. 
Ford Fusion in Pennsylvania, United States
Aug 2008 - Jun 2013
Oct 2008

34000 mi
Drivers seat cushion material developed crack in material. Dealership inpected and immediately ordered/replaced with new seat cover. Warranty repair. 
Ford Fusion in New Jersey, United States
Feb 2010 - Aug 2014
Jun 2010

30000 mi

US $810
Steering pump had to be replaced, making strange sounds. 
Ford Fusion in Texas, United States
Dec 2014 - Jun 2018
Feb 2015

76900 mi

US $75
Failed thermostat 
Jun 2017

87000 mi

US $500
Engine Mounts Failed and Replaced Transmission mount failed and replaced 
Ford Fusion in New York, United States
Oct 2007 - Jun 2011
Mar 2009

47000 mi
I had rust under the hood lip, trunk lip and drivers side rear door. 
Ford Fusion in Indiana, United States
Apr 2007 - Apr 2012
Jul 2008

19000 mi
Fan cycled on/off at high speed with AC running. Found TSB and replaced defective fan. Wiper blade would not clean left side of window. Dealer apparently adjusted wiper blade now works well. Door wind noise. Dealer adjusted door seal. Transmission abruptly downshifts at time. Dealer could not find anything wrong. 
Ford Fusion in Maryland, United States
Nov 2010 - Apr 2011
Dec 2010

67000 mi

US $176
Engine would not reach proper operating temp. Replaced thermostat. 
Ford Fusion in New York, United States
Aug 2007 - Jan 2014
Oct 2007

17000 mi
Popping noise coming from speakers whenever brake pedal was pressed. TSB 07-13-1. Successfully repaired. 
Jul 2009

62000 mi
Shifting sensor malfunctioned 
Sep 2010

119000 mi

US $770
Front right control arms wore out and needed to be replaced. 
Nov 2010

128200 mi

US $770
Front left control arms wore out and needed to be replaced. 
Feb 2013

184700 mi

US $850
Throttle control needed to be replaced. 
Jul 2013

193700 mi

US $920
Oil pan needed replacing (wore out after 193K miles) 
Dec 2013

200000 mi

US $633
Secondary air pump had to be replaced Secondary air injection pump diverter valve needed to be replaced. 
Ford Fusion in Michigan, United States
- Jul 2010
Jul 2010

48000 mi

US $95
Replaced Belt Tensioner and Serpentine Belt. Car was producing a loud high pitched chirping sound when started up and the engine was cold.  
Ford Fusion in Ontario, Canada
Oct 2007 - Apr 2013
Oct 2012

93200 mi

C $600
accessory drive broken - replaced 
Ford Fusion in New Jersey, United States
Jul 2007 - Jan 2012
Jun 2007

US $22000
At 17,500 miles the check engine and wrench light came on. Dealer replaced throttle body, accelerator pedal sensor, and needed additional help from Ford Techline to return the car to normal operation. 
Aug 2008

17000 mi
PCM failed. Needed to be replaced along with throttle body and throttle pedal sensor. 
Aug 2010

48000 mi
Check engine light. P0128 code. Reset code. 
Jun 2011

66000 mi

US $150
DTC Code P0128 - thermostat stuck open. Replaced t-stat 
Ford Fusion in North Carolina, United States
Oct 2007 - Jun 2010
Mar 2009

33000 mi
 
Ford Fusion in Tennessee, United States
Dec 2014 - Jan 2016
Jun 2015

98000 mi

US $1200
Idler pulley bolt failure Tie rods replaced 
Jan 2016

103000 mi

US $500
Second idler pulley bolt failure 
Ford Fusion in Indiana, United States
Sep 2010 - Jun 2014
Feb 2013

63700 mi

US $65
Inside door handle mechanism failed, purchased repair part at Ford dealer. 
May 2014

84000 mi

US $250
Check engine light staying on. Analyst said the engine temp dropped after driving. Thermostat replacement seems to have cleared the error. 
Ford Fusion in Michigan, United States
Aug 2010 - Apr 2012
Aug 2011

160000 mi

US $350
window regulator 
Apr 2012

187000 mi

US $200
thermostat replaced 
Ford Fusion in Utah, United States
Nov 2011 - Jul 2018
Dec 2011

46000 mi

US $33
Heater was always producing cool air. Onboard computer reported P138 coolant under temperature code (i.e. check engine light came on and that was the code it reported). Replaced thermostat. 
Jun 2012

52000 mi

US $15
Received code 491 about secondary air pump failing. Checked hoses for leaks but were fine. Replaced 50A relay to the secondary air pump and problem solved. 
Mar 2013

59000 mi

US $50
Replaced downstream oxygen sensor after receiving code P420 Catalyst system efficiency below threshhold 
Jun 2013

62000 mi

US $75
Engine diagnostic indicated I needed to replace a sensor in the transmission; a Ford Tech said I should just flush the transmission fluid and replace the filter. Replaced the transmission fluid and filter. 
Apr 2014

67000 mi

US $180
Had recurring engine code P0772 shift solenoid E stuck on. Ford mechanic said transmission fluid flush usually solved problem; not so. I replaced the E solenoid, did another fluid flush and replaced transmission filter. 
Mar 2015

78000 mi

US $10
Code P0491 and P0410 secondary air injection system. Not enough air was flowing from secondary air pump; pump is working but air filter was really dirty. Replaced it and hoping for the best. 
Jun 2016

83000 mi

US $20
Replaced the driver side door handle since I was no longer able to open the door from the inside of the car. 
Mar 2017

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. 
Sep 2017

94000 mi

US $75
Transmission fluid flush and replaced downstream oxygen sensor to correct code p0410 
Mar 2018

95500 mi

US $100
Replaced the rear brake calipers, rotors, and brake pads. Replaced battery 
Ford Fusion in Minnesota, United States
Apr 2009 - Apr 2012
Oct 2009

28000 mi
replaced hood latch. hood latch popped up to safety latch twice while driving. Dealer tried to fix but ultimately had to replace. 
Dec 2009

29000 mi
power door lock assembly in front passneger door stopped working,  
Ford Fusion in Virginia, United States
Oct 2011 - Jul 2013
Nov 2011

58000 mi
Replaced #3 coil pack. 
Ford Fusion in Texas, United States
Nov 2014 - Mar 2016
Mar 2016

57000 mi

US $281
Passenger CV axle boot torn 
Ford Fusion in New Hampshire, United States
Jul 2010 - Jun 2015
Aug 2010

41200 mi
timing belt replacement under warranty, brand new goodyear tire inner belt shifted led to steering wheel misalignment, replaced under Goodyear warranty. All performed in Ford dealership 
Nov 2010

46800 mi
Clicking or squeal noise when start up. Noise gone after 15~30min. Detected problem 4 months ago. Dealer replaced a belt. Noise persisted. This week, dealer identified the tensioner was the problem. Replaced tensioner. Noise is gone. 
Ford Fusion in New York, United States
Feb 2010 - Oct 2012
Dec 2010

30000 mi
Check engine came on, later took car to dealer, they discovered that thermostat is bad. Replaced at N/C under extended warranty. 
Ford Fusion in Illinois, United States
Jun 2015 - Sep 2018
Jun 2016

65000 mi

US $75
Thermostat 
Jul 2018

73000 mi

US $759
Evaporations fuel systems Transmission cooling lines Evaporations fuel systems 
Aug 2018

74000 mi

US $850
Transmission cooling lines, valve cover gaskets 
Ford Fusion in Missouri, United States
Jan 2009 - Jun 2018
Jun 2012

91000 mi

US $100
Replaced thermostat under Ford ESP warranty. 
Ford Fusion in Alabama, United States
Jun 2009 - Sep 2015
Apr 2015

115300 mi

US $60
Cooling System--Replaced thermostat 
Ford Fusion in Michigan, United States
Nov 2010 - Aug 2014
Mar 2011

97000 mi

US $58
Mechanic noticed issue. Dealer replaced control arm. 
Sep 2011

108000 mi

US $624
Check engine light was on. Dealer diagnosed the problem as thermostat failure and MAP sensor. Replaced thermostat and cleaned MAP sensor. 
Ford Fusion in Michigan, United States
Jul 2014 - Jul 2016
Oct 2014

91000 mi

US $300
Received P0128 Code for Coolant Temperature Low. Took to shop and replaced Thermostat. Very common issue on 2.3L I4 Ford Fusions for this model year. 
Aug 2015

102800 mi

US $10
Replaced Slide Pin Bushings on Rear Caliper slide pins due to swelling causing excessive brake drag. 
Jul 2016

115000 mi

US $400
Noticed a fluid leak and upon further inspection discovered Transmission Oil Cooler line developed a leak where the rubber hose from the transmission connects to the steel tubing that goes to the transmission cooler on the radiator. 
Ford Fusion in New York, United States
Oct 2008 - Mar 2012
Dec 2008

31414 mi
Fuel Cap Sensor light stuck on. Dealer replaced Cannister Vent Solenoid Assembly at no charge under bumper to bumper warranty. 
Sep 2011

67000 mi

US $40
Light assembly illuminating the rear license plate died. replaced -- cost under $40. 
Mar 2012

70000 mi

US $384
Serpentine belt and belt drive pulley were squeaking. Both items were replaced. Heat shield was making a rattling noise from under the car while traveling at highway speeds. There is a TSB from Ford on this issue. Heat shield was re-secured. 

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2007 Ford Fusion 4-door

6-cylinder automatic 2WD

Ford Fusion in New York, United States
Apr 2007 - Mar 2010
May 2007

2000 mi
Squeaky pass. seat when someone is sitting in it and on left turns. 
Aug 2007

3000 mi
Seat was repaired 3 times by dealer they used fords tsb finally the squeak is gone.for how long i do not know.  

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2006 Ford Fusion

Engine not specified

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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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

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 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 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 Saskatchewan, Canada
Jan 2007 - Apr 2015
Mar 2014

116560 mi

C $2600
Overheated ignition coils, required computer replacement as per TSB. 
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 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 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 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 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 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 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
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 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 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 Quebec, Canada
Nov 2006 - Mar 2009
Ford Fusion in Texas, United States
Aug 2009 - Jun 2018
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 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 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 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. 
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 Ontario, Canada
Jul 2016 - Jul 2017
Jul 2017

97340 mi

C $530
Damaged tie rod. Also need to replace brake disks. 
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 New York, United States
May 2006 - Jun 2015
Jul 2014

123000 mi

US $40
license plate light fixture, state inspection item. 
Ford Fusion in Connecticut, United States
Jan 2006 - Jun 2018
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 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 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 Minnesota, United States
May 2010 - Jun 2018
Mar 2018

299000 mi

US $750
Needed new shocks...they were the originals! 
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 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 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 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 Illinois, United States
Feb 2009 - Nov 2015
Nov 2014

175000 mi

US $340
Ignition coils replaced. 
Ford Fusion in California, United States
Apr 2015 - Jan 2017
Jul 2015

92000 mi

US $1100
Replace tires, struts and shocks 
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 Ohio, United States
Dec 2014 - Aug 2018
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 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 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 New York, United States
- Aug 2007
Aug 2007

9000 mi
Noise from driver side door. 
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 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 Jersey, United States
Jan 2015 - Jun 2018
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. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

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 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 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 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 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 Michigan, United States
- Oct 2008
Oct 2008

50000 mi

US $1000
Bad plug coils 
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 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 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 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 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 South Carolina, United States
Jun 2010 - Jun 2011
Dec 2010

104000 mi

US $1300
Clutch went out. Throwout bearing failed. Starter. 
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. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

Ford Fusion in Iowa, United States
Jun 2006 - Jun 2018
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 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 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 Iowa, United States
- Jul 2007
Jul 2007

15000 mi
steering wheel radio functions wouldn't work correctly 
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 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 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 2018
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
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 Virginia, United States
Nov 2007 - Jun 2018
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 
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 New York, United States
Jul 2009 - Jun 2018
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 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
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 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 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 
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 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.  

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2006 Ford Fusion 4-door

6-cylinder automatic 2WD

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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2006 Ford Fusion 4-door

4-cylinder manual 2WD

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.

2009 Ford Fusion Repair Histories

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 2009 Ford Fusion problems occur, check out our car reliability stats.