Ford Fusion Ford Fusion

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Ford Fusion repairs by problem area

Engine (25%)

Transmission and Drivetrain (12%)

Brakes and Traction Control (4%)

Suspension and Steering (8%)

Electrical and Air Conditioning (28%)

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

Other (8%)

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

Ford Fusion suspension repair cost distribution

$2500+ (1%)

$1000 - $2499 (11%)

$500 - $999 (17%)

$100 - $499 (38%)

< $100 (34%)

Chart based on 127 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2017 Ford Fusion 4dr Sedan

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

20000 mi I have taken it to the dealership a couple times now. At around 40-45 mph the steering wheel will shake and I can feel the shake from the driver seat. Also, when make turns I can hear and feel something catching in the steering. When pulling into a parking spot I can hear a aluminum hitting something sound. Took it to the dealership and they of course say the vibration seems normal and that they could not replicate the sound. 

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2015 Ford Fusion 4dr Sedan

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

20624 mi Rear struts and strut mounts were clunking and were replaced 
36000 mi Right rear wheel bearing started making noise. Car was still under bumper to bumper warranty and did not cost us anything I do not know what the cost of repairs was. They also performed the yearly safety inspection required in Maine at no cost to us. They are a super great dealer !!! 

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2015 Ford Fusion 4dr Sedan

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

37820 mi Suspension was squeaking over bumps, it took 6 visits to the dealership and my finally taking them out and showing them the noise for them to diagnose it was the shocks 
9000 mi One wheel had a rattle when turning right. Unsure what was done to fix it, but it was a very minor problem. 

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2015 Ford Fusion 4dr Sedan

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

Front strut defective, started leaking. Replaced under warranty. Loaner was provided. 

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2014 Ford Fusion 4dr Sedan

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

29000 mi Rear left hub bearing replaced. 

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2014 Ford Fusion 4dr Sedan

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

18500 mi Replaced rear passenger shock and mounting bracket because of metallic noise over potholes. Problem still present. 
18300 mi

US $250
Noticed right rear ball bearing noise, took to shop. Found bent right rear rim, replaced bearings and re-aligned. Covered under insurance. Days later noticed front bearings needed to be replaced. Covered under warranty. 

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2014 Ford Fusion 4dr Sedan

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

17000 mi Power steering (and traction control) went out one day. Dealer replaced a steering gear. 
60000 mi

US $120
Replaced rear shocks due to rear end noise. 

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2014 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

38000 mi

US $140
leaking shock absorber 
51000 mi Previously replace shock absorber started leaking fluid 

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2013 Ford Fusion 4dr Sedan

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

45000 mi

US $300
Noise from rear- could not diagnose 
30380 mi Replaced rear shocks 
58000 mi

US $300
Left front wheel hub assembly broke. 

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2013 Ford Fusion 4dr Sedan

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

53900 mi REPLACED BAD SHOCKS 

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2013 Ford Fusion 4dr Sedan

turbocharged 178hp 1.6L I4 6-speed manual FWD

26000 mi

US $86
Knocking noise from steering during parking lot maneuver. Steering bolt broke and replaced but parking assist still inoperative. Navigation unit frozen. Reprogram navigation and my ford touch system. Airbag control and door latch recall. 
29000 mi replaced electronic power steering system to resolve parking assist. Did nit resolve the issue due to software incompatibility with manual transmission. 
91349 mi

US $250
Sway bar loose. 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

9300 mi Steering clunk when backing up, turning right and gently applying the brakes. Dealer could hear sound but doesn't know what's causing the clunk. They claim it's nothing to worry about 
18000 mi Steering clunk, axle replaced. Didn't fix. Clunking sound present, TSB called for adding some shims to wheel hub. Noise fixed. 
26000 mi Power steering failure 
48000 mi Separated wheel bearing and bad axle bearing (front right). Axle assembly and wheel bearing replaced. 
18000 mi

US $90
Required re-alignment after transmission fix. Was never done correctly by original dealer, so took to another dealer to fix correctly. 

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2012 Ford Fusion 4dr Sedan

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

21700 mi

C $50
Sensor failed. To replace sensor needed to replace steering gear. Would have been $2,400 if the extended warranty hadn't paid. 
124000 mi

US $100
Bad wheel bearing-replaced 
75000 mi

US $100
Front upper shut mounts were making noise when the wheel was turned in parking lot maneuvers. After upper strut mounts were replaced, the noise was still present. 
75000 mi Suspension noise never fixed. 
20000 mi Clunk from left front when hitting dip in road while turning and braking. Dealer reproduced at first but nothing found when inspecting the suspension, but later could not reproduce noise at all. Got car back and issue returned in a day. 
38000 mi

US $600
Both lower control arms replaced due to worn bushings. (bushings are press-fit into the arms, and cannot be replaced separately) 
45000 mi

US $650
Dealer diagnosed noise as faulty steering gear, related to recall 15N01, but no DTC codes present, so not directly covered. Submitted the information to Ford customer service and they agreed to split the cost of repairs. 

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2012 Ford Fusion 4dr Sedan

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

3620 mi Loss of power steering, known EPAS issue, steering box replaced under warranty 
105400 mi problem with sway bar blots for toe wheel adjuster ect. 

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2012 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

37000 mi My car began making a 'knocking' noise at low speeds when stopping, accelerating or turing when temps reached 80F. Turns out it was defective front control arms. Dealer was nice - giving me an extension of the warranty so I had $0 to pay. 
74000 mi

US $150
Replaced driver side lower control arms 
107000 mi Replaced steering gear after started getting "steering system fault" warning lights. Covered under extended recall warranty. 

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2012 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

29000 mi

US $2155
Replaced electronic assist power steering module 

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2011 Ford Fusion 4dr Sedan

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

13300 mi Car pulled to the left. Had to replace a control arm. 

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2011 Ford Fusion 4dr Sedan

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

74000 mi

US $1900
Electric rack and pinion system died. Replaced power steering assembly. 
74000 mi

US $365
Control arms make constant noisy creaking sound. Dealership said nothing wrong with the car; that it was caused by the control arm bushing drying out. They said they could "fix" it for $1700 in control arms, or they could try lubing it. 

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2011 Ford Fusion 4dr Sedan

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

47120 mi

C $383
Noise form driver side, replaced one arm. Joint ball of passenger side suspension torn, replaced. 

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2011 Ford Fusion 4dr Sedan

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

95000 mi

US $1579
passenger front hub assembly required repair 
106000 mi

US $675
Noise and inability to do an alignment due to excessive wear. 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

37000 mi strut clunking 
49000 mi

US $205
Right front lower control arm ball joint failed inspection. 
64500 mi

US $100
Steering wheel rack failure which made the power steering inoperative 
104000 mi

US $520
Loud creaking in front-end at slow speeds. Replace all four lower control arms. 
105000 mi

US $1500
Left and right control arm bushings worn. Replaced both control arms. 
68000 mi

US $450
Lower control arm bushing cracked. 

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2010 Ford Fusion 4dr Sedan

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

95700 mi Rack and pinion was leaking from the boot. Completely replaced rack and pinion under extended warranty. However had to pay for system flush and alignment out of pocket. 
41100 mi Steering briefly shuttered and groaned during a full turn - per service manager, problem found was loose power steering hose resulting in low fluid. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

112840 mi

C $450
Pothole damaged front passenger? wheel bearing and tire 
119040 mi

C $480
Rear driver wheel bearing noisy, found to be damaged and had to be replaced. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

61000 mi bearings replaced - took to shop some months prior but mechanic didn't hear the noise so no action. This time they did. 
20900 mi Rear suspension would 'bottom out' on almost any sized bump. Took to dealer; they determined that both of the rear shocks were leaking. Shocks were replaced under warranty. 
21700 mi 19-Oct-10 35500 km Problem detected when I saw lubrication fluid spots under car while parked in my driveway. Driver side front axle seal gone and leaking fluid. 
99820 mi

C $2234
Power assist steering went out again, 22 days since the same trouble was repaired. This time they say the rack and pinion is gone and needs replacing. Very expensive repair and known trouble by Ford but they refuse to accept responsibility. 
105400 mi

C $150
Both wheel bearings replaced 
120500 mi

C $300
Both sides have tie rods with excessive play in them. 
154360 mi

C $637
replace both outer tie rods 
4960 mi The car had to be taken in several times for them to diagnose and fix the problem, also the dealership caused a problem while fixing the first issue 
139000 mi

US $1100
Front spring cracked. Replaced both springs and struts 
137500 mi

US $40
replaced both outer tierods 
57660 mi

C $200
Cracked spring on left front. Replaced whole strut/spring assembly for ease of repair and cost. 

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2010 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

56800 mi

US $460
Bent wheel bearing replaced. 
64000 mi

US $650
Cracked wheel bearing; made a grinding noise when making turns. 
85000 mi

US $387
Left front wheel hub bolt was loose, causing noise when front wheels were turned. This could of been a series problem if I (owner) did not notice the noise and take it in for inspection and repair. 
87000 mi

US $1400
car started making noise about 2 months after last repair. Both front wheel bearings needed to be replaced. I suspect dealer may have botched initial repair job. 
90000 mi

US $300
tie rod replacement 
97100 mi

US $95
Power steering and AdvanceTrac systems flashed warning lights. Car automatically disabled power steering and AdvanceTrac. Dealer reset warnings, recommended replacement of steering rack. 
54000 mi Right-front wheel bearing was making a little noise on slow turns but was otherwise unnoticed. 

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2009 Ford Fusion

Engine not specified

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). 

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2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

130000 mi

US $200
Left front wheel bearing required replacement. 
3000 mi car drifts to right 

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2009 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

83700 mi

C $500
Replace 2 front wheel bearings 
56480 mi

C $215
replaced both rear stabilizer bar end links 
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. 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

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. 
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. 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

105000 mi

US $150
Wheel bearings went bad on the front end. Both were replaced. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

52320 mi

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

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

82000 mi

US $215
Replace both tie-rod ends 
52200 mi

US $350
Front and rear sway bar end links worn out causing a rattle going over uneven surfaces. 
60000 mi

US $150
Had to reposition the the left front strut spring sadddle rubber on bottom, slid out of position. 
80000 mi

US $697
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 :) 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

118000 mi

US $1000
Replace both tie rod ends. Steering wonky. replace sway bar links - front. Making noise 
186000 mi Wheel bearings, front. 
197000 mi Wheel bearings, rear. Power steering pump and pressure hose. 
206000 mi Power Steering pressure switch failed. 
80000 mi

US $250
Drivers side front lower control arm replaced due to noisy bushing. 
118700 mi

US $100
Tie rod bushing and axle boot ripped. Probably caused because car has been lowered for almost 100k miles 
132500 mi

US $100
rear shocks worn out (rear end very bouncy whenever even light load present), replaced shocks 
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. 
96000 mi

US $200
Replaced control arms to resolve ball joint creaking noise issue 
77900 mi

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

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

118500 mi

US $230
Squeaking and uneven tire wear caused by worn out struts. Replaced front struts and rear shocks. 
166000 mi

US $200
Right front wheel bearing 
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 
31000 mi A bearing went out in right rear axle. 
109740 mi

C $200
Ball joint went, replaced entire control arm as it was easier. 
47120 mi

C $1600
Replace wheel bearings front and rear. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

122000 mi

US $500
rear upper control arm struts and shocks 
65000 mi

US $300
Left axle shaft (that turned out to not be the problem) and left front wheel bearing. 
103700 mi

US $260
Right front wheel bearing replaced 
55180 mi

C $340
There were clunks when entering driveways etc. 

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

30000 mi

US $810
Steering pump had to be replaced, making strange sounds. 
97000 mi

US $58
Mechanic noticed issue. Dealer replaced control arm. 
119000 mi

US $770
Front right control arms wore out and needed to be replaced. 
128200 mi

US $770
Front left control arms wore out and needed to be replaced. 
6820 mi Suspension sounds wrong. 
98000 mi

US $1200
Tie rods replaced 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

88440 mi

C $700
Replaced both tie rod ends. Replaced right side upper ball joint. 
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. 
96400 mi

US $560
Both front hubs replaced, passenger hub mount also replaced as hub was seize-rusted on. Also replaced oil pressure switch. 
142000 mi

US $300
rack and pinion replaced with used oem 
107800 mi

US $195
technician found and replaced worn sway bar links. preventative maintenance, 100k service replaced spark plugs, flushed coolant system and transmission.  
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 
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!!!!! 
82000 mi suggested replacement of bar. repair too expensive, so I decided against the repair 
103000 mi suspension creaking. mechanic idicates the control arm may need to be replaced 
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. 
95800 mi

US $1100
Replace tires, struts and shocks 
123380 mi

C $350
struts replaced. 
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. 
97340 mi

C $530
Damaged tie rod. Also need to replace brake disks. 
117000 mi

US $20
Tie Rod end (both) boot torn. Replaced. 
124500 mi

US $1
Right strut bearing made horrible noise. Injected lithium grease and all is fine. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

92480 mi

C $1000
Front struts worn out 
96000 mi

US $120
Clunk in steering and during acceleration and braking. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

25000 mi Creaking noise in front suspension 
110000 mi

US $1800
control arms replacement 
98000 mi

US $360
wheel hub worn 
139000 mi

US $370
lower control arm (front right) replaced 
162000 mi

US $500
replaced front struts, worn 
172000 mi

US $500
Replaced front struts due to noises. Still may have to replace tie rod ends. 
197000 mi

US $3500
Replaced, struts (4), front rotors and pads. A arms lower control arms (4), stabilizer links, tires 

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Ford Fusion Suspension Problems

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