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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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Need advice about specific Ford Fusion problems?

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

Ford Fusion transmission repair cost distribution

$2500+ (2%)

$1000 - $2499 (6%)

$500 - $999 (11%)

$100 - $499 (18%)

< $100 (63%)

Chart based on 142 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2016 Ford Fusion 4dr Sedan

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

AWD failure indication. 
12400 mi PTU passenger side wheel seal leaking, seal changed and no leaks since. was in for oil change last week about 4 weeks since repair and still no leaks 
25000 mi Transmission shifts hard into lower gears, this is worse on a cold start. In addition, on colder days it slams into gear between 2nd and 3rd on upshift and downshift. 
18000 mi Solenoid in transmission was replaced due to hard shifting conditions from park to reverse and hard up/down shifts from 3rd to 4th gear. TSB is available, the dealer told me more than once there was nothing wrong until I searched and found the TSB myself, they then agreed to perform repair. But quirks now returning two months later. 

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2016 Ford Fusion 4dr Sedan

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

250000 mi Noted a surging or hard downshift at 50-60mph. Dealer confirmed, but said it was operating "normally." The service adviser also said others had the same problem, so ask if there is a service bulletin for an updated transmission software at my future visits. 

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2014 Ford Fusion 4dr Sedan

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

6000 mi Various parts needed to be replaced inside transmission due to slippage in first three gears. Problem was aggravated by the cold weather. 
15000 mi Harsh shifting Trans, missing Rev matches, and occasional hesitation. Also radio volume increasing with no driver input. Supposedly dealer performed PCM software update and reflash of My Ford touch software. Volume:fixed, Trans: not fixed 

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2014 Ford Fusion 4dr Sedan

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

35500 mi Drive axel boot seal leaking. Replaced seal with new one 

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2014 Ford Fusion 4dr Sedan

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

31000 mi Drivetrain repair 

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2013 Ford Fusion 4dr Sedan

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

8000 mi Slips between 1st and 2nd gear, Left it at dealer for a few days and If the computer does not give error code or check engine light they cannot do anything about it. It is obvious that it slips and sounds different between 1st and 2nd gear. 
7000 mi Transmission valve malformed and popping when put into reverse. 
12000 mi TSB performed for CV click with thrust washer. Took dealer "forever" to source parts on common repair. 
9000 mi when shifting from forward to reverse (or vice versa), clack or click sound from front wheels. Sounds similar to pads sliding around in caliper, but is NOT that. Found TSB 13-5-24 on blue oval forum. Needs thrust washers on half shafts. 
25000 mi There is a "squish, squish, squish" rhythmic noise coming from the drivers side, noticeable coasting at 10mph with the window down. Sounds like is coming from driver front wheel. 
34300 mi rhythmic noise from drivers side still there 
7000 mi Clicking noise when putting into drive. Replaced thrust washers in transmission. There was a TSB for this repair 
23000 mi would get stuck in 2nd gear. 2-3 shift hard. 
20460 mi Replaced defective part 
22300 mi Half shaft TSB 
42700 mi Clicking noise from front left while turning. Dealer diagnosed as differential problem. Differential replaced, but problem returned within a day of picking up the car. 
44000 mi Clicking noise remained after differential replacement. Dealer found TSB for CV axle replacement. Driver side CV axle replaced. 

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2013 Ford Fusion 4dr Sedan

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

26000 mi repaired oil leak on axle boot 
40000 mi Transmission shifts harshly, most noticeable in the 2->3 shift. The transmission learning memory was reset. The harsh shifting was lessened, but not removed, for a while but seems to be returning. 

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2013 Ford Fusion 4dr Sedan

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

50000 mi Replace control and solenoid assemblies 
26000 mi The car went into sort of limp mode and I was not able to accelerate over 2000 rpm. A wrench symbol popped up on my dash which indicates transmission issues but goes away when I turn off the car. 
42500 mi

US $680
leaking seal on the drive shaft exiting the transmission 
21080 mi Transmission software updated 

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2013 Ford Fusion 4dr Sedan

turbocharged 178hp 1.6L I4 6-speed manual FWD

58000 mi Manual transmission output seal leak. Part backordered hence 4 days stay at dealership. 

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2013 Ford Fusion 4dr Sedan

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

37300 mi When car is cold, car shifts hard from 4 to 5 
44000 mi Reported problem in April 2014 continued....When cold, car would jerk when shifting 4 to 5th...Vista Ford of Oxnard took tranny out and replaced a solenoid assembly...Was a Technical Service Bulletin...... 
44000 mi Problem still present even after Fourth of July repair..Vista Ford of Oxnard rebuilt tranny, meaning replaced valve body and clutches and flushed cooler lines due to debris..... 

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2013 Ford Fusion 4dr Sedan

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

17000 mi Hill-holder not functioning. I suspected that it was accidentally disconnected internally as a result of a prior repair. I was right. Dealer connected the wires and reassembled the center console and this fixed the problem. 

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2013 Ford Fusion 4dr Sedan

141-horsepower 2.0L I4 Hybrid CVT FWD

5000 mi Grade assist would periodically stick on. Dealer scanned for codes, took for test drive. Computer did not store any codes. They did not reset anything. 
18000 mi PCM needed to be replaced because it died. 
4000 mi Clicking noise from front half-shafts - fixed as part of TSB for both left and right side Hybrid Powertrain reprogrammed as part of customer satisfaction program to improve hybrid mileage. 
34000 mi Leak at split case seal. 
8000 mi

US $20
Transmission is leaking. Dealer claims that it is just "seeping" and not dripping and thus there is "no problem". They consider the huge wet spot on the panel to be "normal". They ignored the Ford TSB about this issue. 
8000 mi Transmission seal seeping. 
15900 mi Transmission seal leak (eCVT) . Known issue for some hybrids, repaired under warranty. 

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2012 Ford Fusion 4dr Sedan

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

8680 mi Tranny shifting rough. Axle seal leak discovered. Replaced 
31600 mi Erratic shifting 
59000 mi

US $100
Right front axle seal was leaking. Repaired under Ford extended warranty. $100 deductible. 
4000 mi vehicle is not shifting correctly, slamming gears and over revving between shifts vehicle still not shifting properly, data recorder was installed then removed after a few weeks. 
34100 mi transmission seal defect, transmission was leaking 
46500 mi transmission seal again!! on warranty 

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2012 Ford Fusion 4dr Sedan

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

75000 mi

US $2200
AWD PTU was whining and smelling horribly. PTU needed to be replaced as it is a non-servicble part. 
44640 mi Vibration in drivetrain at 89 t0 80 km car is with ford Engineering had problem with this at 269 km when car has new been fighting for two years. need help. Update: replaced driveshaft with updated part. 
78960 mi same vibration in drivetrain and transmission slipping and banging, everthing but the engine was changed still have the samr problem. 
84320 mi same on going problem with transmission slipping and vibration in drivetrain. axle replaced, was making a noise 
92380 mi axle and steady bearing on going problem with this car, still have transmission vibration. 
97700 mi after another attempt, transmission slipping and big loud bang from drivetrain. happened on the highway. doesn't seem safe. 
104160 mi vibration in drivetrain. transmission, brakes, trans slipping and banging engine 
104360 mi

C $80
Had transmission rebuilt again and driveshaft replaced again. 
105400 mi trans mission rebuild again and driveshaft was replaced, had a chunk out of it. car was a problem from when I purchase it new . 
9900 mi SUM: WHEN NEW, VEHICLE EXHIBITED HARSH SHIFTS FROM 1-2. GRADUALLY WORSENED AND CAME TO INCLUDE A SOFT 2-3 SHIFT AND A METALLIC FRICTION NOISE IN LOWER GEARS BY 1000MI. STARTING AROUND 7000MI, VEHICLE STARTED TO SHIFT ERRATICALLY IN TRAFFC 

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2012 Ford Fusion 4dr Sedan

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

3500 mi Erractic shifting/slipping. Reprogrammed powertrain computer 
12000 mi Erratic shifting, shift flares harsh shifts. 

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2012 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

6670 mi Transmission software adjustment Transmission adjustment 
10000 mi Transmission software adjustment 
16000 mi Automatic transmission not shifting correctly. 
23700 mi Automatic transmission not shifting correctly 
78000 mi

US $100
A small transmission leak was detected during annual vehicle inspection. Dealer confirmed and repaired leak. Car is covered under Ford extended warranty so cost was only $100 
10700 mi Harsh shift 1-2, slipping and flaring 2-3 and 3-4 despite application of TSB 12-3-7 Failure of valve body due to worn regulator valve bore. Total rebuild with replacement of all clutches, gaskets, and seals, including foward, reverse, overdrive clutches and final drive seal. Vehicle in shop for 21+ days. 
18000 mi Further work up for harsh 1-2 shift, now only when cold. Vehicle pressured tested and passed. PCM update applied. 50 percent improvement. 
31000 mi Continued harsh 1-2, flared 2-3, and other shift quality issues. update: Ford declared normal operation and I let it go.  
61938 mi Stuttering tach at 1600rpm Stuttering tach at 1600rpm 

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2011 Ford Fusion

Engine not specified

23000 mi Half Shaft Transmission Fluid Leak 

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2011 Ford Fusion 4dr Sedan

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

52000 mi Trans was shifting hard at times going into second. 

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2011 Ford Fusion 4dr Sedan

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

51000 mi

US $730
Front right axel 
46000 mi Transmission operation was very displeasing. Hard shifting, hunting for gear, gear hopping when stopped in gear, so on. Taken to dealer, supposedly the TCM was updated to the latest software (TSB). Issues continue, but to a much lower degree. 
44000 mi Odd shifting habits and other strange transmission behavior. Changed fluid again with a different type just prior to accident which took car out of my possession. 
14000 mi Transmission slipped between 2nd and 3rd. Software update. 
16000 mi Transmission slips in change from 2 to 3 when cold. Told this is normal by dealer. 
25300 mi

US $734
Firmware update to improve shift quality. 
124000 mi

US $350
Cooling lines for the transmission were leaking 

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2011 Ford Fusion 4dr Sedan

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

37000 mi Transmission was shifting hard. Dealership couldn't find any issues, however they reprogrammed the transmission computer. This fixed the problem. 

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2011 Ford Fusion 4dr Sedan

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

38000 mi Axle seal for right drive shaft 

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2011 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

92100 mi

US $1500
Cracked and leaking transmission cooler lines replaced 
24000 mi Slams into 3rd gear when cold. Retimed shift points. 
9100 mi Occasional Hard shifting 
44000 mi

US $250
Shifter broken. It is going to cost $400 to replace it. I have been trying to convince Ford to pay for the replacement since it failed with only about 43,000 miles. So far it has not agreed to it. 
32000 mi Heavy clunk when shifting from park into reverse or reverse into drive. 
96900 mi

US $350
The valve body cover was leaking. Fluid drained, cover removed and resealed. Had transmission flushed but didn't include that in the repair cost. 
70000 mi

US $270
Replaced drivers side CV shaft seal on transmission and internal bushing. 

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2011 Ford Fusion 4dr Sedan

156-horsepower 2.5L I4 Hybrid CVT FWD

40920 mi It was impossible to shift to P, The car was turn-off in N, after that I wouldn't start. The dealer reset it and it worked fine again. 

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2010 Ford Fusion 4dr Sedan

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

22400 mi

US $89
hard shifting, re programmed software. 
9000 mi Transmission replaced but didn't solve problem: slipping while going uphill, hard shifting. New transmission removed twice, replaced valve body, solenoid, and PCM, still didn't solve problem. Hav refused offer to replace trans again, want buyback. 
11000 mi I finally agreed to allow Ford to install yet another transmission. This one at least appears to have resolved the issue. 
18000 mi The transmission slammed into reverse. I have had and apparently continue to have problems with my transmission.  
73000 mi

US $200
Recall to recalibrate Throttle Body Sensor. 
29300 mi Replaced rear seal transmission 
38000 mi Black and burned transmission fluid requiring flushing 
110360 mi

C $600
My 2010 Fusion was leaking transmission fluid, turns out the left axle seal was bad and they had to replace the whole unit. 
54000 mi I was getting some random, intermittent shift-slippage that would have led me to take the car in for service had I not traded it in. 
59000 mi

US $80
Car made grinding noise when turning right. Replaced the driver's side CV axle myself (after watching YouTube video). 
12200 mi Overdrive piston in transmission problem - replaced under warranty along with ancillary parts. Basically a significant transmission service/rebuild. Problem was missing gears during acceleration. 
8000 mi Transmission started slipping upon heavy acceleration, took into Ford dealer who were not easy to deal with.... Next day they said they were replacing valve body - common failure among 6F35 transmission. 
10000 mi Car came back with a transmission whine upon running at full operating temperature. Transmission fluid level was also found too high, but that did not relate to the whine, car still has to go back. 
18000 mi Transmission is still acting up, hasn't been right since 1-2010, dealer cannot fix it. 
19000 mi Car is a lemon - faulty transmission since January 2010 
22000 mi Transmission was slipping severely and "whining". Car went in for transmission overhaul and after a week problems are just as bad again. 
26000 mi Transmission whining, very obvious and everyone BUT Ford dealer acknowledges it. 
32000 mi Transmission failing to shift on highway. Severe slipping and banging. Failure to reset to 1st gear at stops when coming off highway 

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2010 Ford Fusion 4dr Sedan

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

80000 mi

US $237
Had to re-flash the transmission due to rough shifting. 
19840 mi Drivetrain noise when shifting from reverse into drive, and failure of transmission to 'kick down' when accelerating from stationary position within reasonable time period. 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed manual FWD

35000 mi Complete replace of transmission 
1000 mi Dealer damaged transmission. Ford Corporate Rep denied replacement tranny on a vehicle with 1000 miles & ordered a repair only. Tranny was replaced because parts were unavailable for 30 days or more. Ford Customer service Hot line was uncooperative. Manual Transmission failure. Transmission was replaced. 
2000 mi Clutch needed adjustment after the transmission was replaced earlier in September. 
32300 mi Grinding gears when shifting from 1st to second at high rpms. 
39000 mi Occasional grinding shift from 1st to 2nd gear 

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2010 Ford Fusion 4dr Sedan

175-horsepower 2.5L I4 6-speed automatic FWD

10000 mi Complete transmission replacement; covered under warranty. 
1900 mi TSB installed to correct transmission "flairing" when cold. TSB was successful. 
37000 mi

US $210
Engine check light. Dealer said error was for transmission and firmware update fixed it. 
51000 mi Occasional "flare" (momentary increase in rpms as if missing a shift with a std. trans.). This didn't happen very often though. 
59000 mi transmission fluid leak was detected when I went in for an oil change. There is a TSB on this, leak on left side, and some parts were replaced. 
51000 mi codes p0753,p0219,slipping in 4th and 5th gear; remove transmission and overhaul unit; transmission fluid leaked allover my drive way returned to dealer for further repairs 
31000 mi transmission acting weird @below 5km/h in stop and go traffic when engine is hot. 
95960 mi

C $275
Transmission lines were rusted and leaking in 2 location. New transmission lines installed. 
21700 mi Recently noticed a leak under the car and my RPMs jumping as I accelerate. Turns out my axle seal needs to be replaced and transmission fluid is leaking. According to the service mgr (and what I read on the internet), Ford is aware of it. 
41000 mi

US $3100
Took car for oil change; shop noted tranny fluid leak and no fluid. Went to AAMCO; fluid gone, needed new gears,torque cvtr,axle,bushing and half case: $3100. Known problem:TSB-14-005. Vehicle 3 mo out of warranty. Ford: "Too bad for you." 
128300 mi

US $10
Driver side bushing and seal replaced..Was leaking trans fluid.... 
39000 mi Transmission hard shifting. Reflashed computer, and fixed shifting problem. However, it was leaking transmission fluid. Ended up replacing the half shaft (under warranty), as it was cracked. 
34000 mi harsh shifting, trouble finding the right gear 
42000 mi Continued Harsh Shifting/Skipping, lack of power 
32300 mi Intermittent transmission problem. Jumps out of gear at high speeds (around 70 mph). Dealer not able to replicate. Third time in for repair. 
34000 mi Transmission shifted hard on occasion. Car would fail to downshift gradually as I coasted to a stop, leaving me with no torque, then would slam down into gear. 
83000 mi

US $179
Was told there was a TSB on throttle software. They reflashed the system 
21000 mi Took it in for harsh 2-3 shift and intermittent RPM flare between same shift. Was told could not duplicate. 
22500 mi Took back to dealer a few days later after voicing displeasure with last repair trip. They kept the car for 4 days and still told me they couldn't duplicate the problem. Less than pleased with Ford and this troublesome 6F35 transmission. 
92000 mi

US $600
Brought in with harsh shifting after adding 1.5 quarts of fluid. They couldn't find a leak and advised that the fluid was badly burnt. They also changed other fluids during this visit 
100400 mi

US $400
Transmission leak found. Replaced drivers axle seal 
26740 mi Right front axle seal leaking. Removed RF wheel. Disassembled front end, left lower ball joints intact. Removed axle. Removed and replaced seal. Reassembled front end. Replaced axle nut and torqued to spec. Topped up trans oil. 
11000 mi Transmission problems - clunking noise/feel when changing gears. Shop could not replicate nor did codes show anything wrong so nothing was done. 
71000 mi Transmission would clunk when slowing down and started shuddering when accelerating or decelerating. Dealer could find nothing wrong. It had this problem since 25,000 but became more and more frequent. 
27000 mi The transmission was shifting from 3 to 4 harshly. The dealer reprogrammed the automatic transmission and that seems to have worked. 
24000 mi Experienced hard shifting from 1-2 and 2-3. Shift flare from 3-4 at times. Reprogrammed PCM as per 3 TSBs. Repair seemed to help the issue, but not completely resolve it. Returned from ~1,000mi round trip. Hard shifts and shift flaring returned. Took to dealer, was notified that transmission would have to be replaced. Overdrive clutch and others burnt up. Fluid was black. Replacing torque converter & trans. 
46400 mi Axle Seal Leak, seal and other other components replaced per TSB. Transmission Fluid Replaced. Replaced leaking axle seal as instructed by TSB 
69440 mi

C $707
Transmission fluid leaking; installed joint and stub shaft, replaced axle bushing and seal. In my view it seemed to be a factory defect and not a usual maintenance repair. Dealer did not want approach Ford for partial reimbursement. 
38000 mi

US $500
Engine would not start after towing. Dealer said it was towed in gear. Transmission burned up. New one on order. 

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2010 Ford Fusion 4-door

4-cylinder automatic 2WD

68300 mi car is pulled by RV. 4 WHEELS down. I follow Fords instructions. this is 2nd transmission in 10 months. car is still not ready. 
103000 mi Transmission went out for 3rd time. Car sold to dealer. 

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2009 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

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 automatic FWD

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

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

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 
89000 mi

US $550
Transmission lines were badly corroded and were leaking. All three lines were replaced. 
125000 mi

US $700
Left halfshaft was replaced as well due to torn boots. 

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2008 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

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. 
135000 mi

US $350
Leaking trans pan gasket. Replace trans pan gasket flush system, and replace filter. 
76400 mi

US $829
Replaced rear driveshaft due to failed front carrier bearing. 
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! 
38000 mi Carrier bearing failed on the driveshaft (AWD). Entire driveshaft was replaced as a result. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

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. 

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2008 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

68800 mi

US $320
Torn CV Boot 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

139000 mi

US $850
Had to have the valve body replaced in the transmission 
143000 mi Transmission replacement. 
180000 mi Transmission linkage repaired--would not shift out of drive.  
134000 mi

US $746
Leaking under front of car. Transmission Oil Cooler Line had rusted through and was replaced. 
113000 mi

US $200
replace leaking transmission cooler lines that run to the radiator, Slow leak. Showed a red spot under that car when parked overnight. 

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2007 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic AWD

101360 mi AWD car, half shaft joint went, had to replace shaft. 
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 
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. 
140000 mi

US $1100
Failed transfer case was causing loud grinding noise. Needed replacement. 
104160 mi Failed transfer box. 
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

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). 
79000 mi

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

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2007 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

126000 mi

US $120
CV boots have been cracked for about 30k miles. Finally replaced them. They were NOT making any noise. 
19000 mi Transmission abruptly downshifts at time. Dealer could not find anything wrong. 
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. 
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. 
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. 
57000 mi

US $281
Passenger CV axle boot torn 

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2006 Ford Fusion 4dr Sedan

221-horsepower 3.0L V6 6-speed automatic FWD

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. 
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). 
134000 mi

US $400
Trans cooler lines rusted through and were leaking 
104160 mi

C $300
Transmission lines replaced (leaking fluid). 
53000 mi Transmission slipping. Car went to shop and parts were ordered. They will be installed (new transmission) next week. Not under warranty. 
75000 mi

US $465
Transmission slipping--cooling lines had to be replaced 
81000 mi Bad O-Ring on new transmission was faulty, leaking all the fluid out of transmission and car woldn't run. 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed manual FWD

11000 mi The grease used in the cv joints freezes below 20 deg so they replaced both axles. 
104000 mi

US $1300
Clutch went out. Throwout bearing failed. 
90000 mi

US $1750
complete rebuild of transmission assembly and casing complete rebuild of transmission assembly and casing 
99000 mi

US $500
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 

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2006 Ford Fusion 4dr Sedan

160-horsepower 2.3L I4 5-speed automatic FWD

14000 mi transmission range finder was faulty causing transmission and engine to rev at high speeds. 
110000 mi

US $1800
CV boot  
141000 mi

US $400
Right axle, which had been replaced in February 2014, had another failure. 
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 
26000 mi The button to release the shifter did not pop out, leaving the shifter free to move up and down. 
160300 mi

US $500
replaced left and right front cv axle shafts. Both had torn boots 
33000 mi Loose shift selector control handle. 

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2006 Ford Fusion 4-door

6-cylinder automatic 2WD

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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Ford Fusion Transmission Problems

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