Ford Fusion in California, United States Sep 2014 - Sep 2014

Sep 2014 93000 mi US $1100

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

Ford Fusion in Missouri, United States Jun 2009 - Jun 2011
Jun 2010 16000 mi	Took the car in with transmission problems. Updated the software.

Ford Fusion in Montana, United States Jul 2012 - Aug 2012
Aug 2012 38000 mi	There are scratchs on the passenger side front window. Was taken it for this problem in June 2012 had window replaced but problem happen again having trouble getting it repaired now that the warranty has expired.

Ford Fusion in Ohio, United States Dec 2010 - Feb 2011

Feb 2011 8000 mi

I had the reflash done on the transmission and it did not work with my car. Whenever you would shift between gears, I had to wait for 2 to 3 seconds for it to go into gear. If by chance you hit the gas it would slam into gear. Had the coolant bleed twice and it did not work. The auto climate control was reprogrammed and it still did not work. Would blow out cold air as soon as car started, didn't wait for engine to warm up.

Ford Fusion in Wisconsin, United States May 2010 - Dec 2012
Feb 2011 4000 mi	Owner noticed that drivers window would not go down. All other windows worked fine. Fix was to reset the software. The auto-down motor experienced a heavy load due to frost sealing the window. This will become a problem for Ford.
Jan 2012 8300 mi	Steering briefly shuttered and groaned during a full turn - per service manager, problem found was loose power steering hose resulting in low fluid. Owner observed unusual situation with brakes where when brakes applied, coming to stop moving forward then put in reverse, moving then applying brake a noise occurred. I described it to the dealer as a loose caliper- they may have tightened

Ford Fusion in Michigan, United States May 2015 - Jun 2018
Dec 2017 166000 mi US $580	Front Passenger wheel bearing had been making noise which had been getting progressively worse for the past 60,000 miles. Replaced both front wheel bearings. Noise is subsequently gone.

Ford Fusion in North Carolina, United States Sep 2009 - Feb 2021
May 2011 21000 mi	Trim on buttons on right side of steering wheel was just slightly loose. Asked Dealer to replace not so much that it bothered me, but 1) technically a defect 2) didn't want it to break more in the future. Fixed and sturdy now.
Jun 2011 22000 mi	Inside driver door handle broke, dealer replaced during initial visit to deal with problem.
Aug 2011 25000 mi	Driver seat lumbar area was squeaking. Dealer had upholstery removed and insulation added so that the squeak stopped.
Apr 2012 34000 mi	HVAC blower/motor was making a twittering sound, sometimes very high pitched. Dealer replaced blower. The dash was making a buzzing sound on hot afternoons. I noticed a piece of trim/bezel next to the radio stack was creaky on the left side but not the right side. Dealer firmed it up and so far it's better.
Jun 2013 47000 mi US $111	Battery wouldn't hold a charge when car was off for more than a couple of days. Diag showed bad battery. Factory battery warranty ends with car warranty. Replaced with new battery from Ford (which has a nice long warranty).
Sep 2017 87000 mi US $75	Battery not holding charge. Prorated and replaced. However, new battery only has remainder of previous battery warranty.
Dec 2019 99 mi US $900	Noises from front of car. Replaced front CV axles and front right wheel bearing.

Ford Fusion in California, United States Oct 2012 - Mar 2021
Jul 2014 85000 mi US $75	Tire sensor replaced.
Nov 2014 90000 mi US $850	Vibration, worn transmission mount, replaced Tire sensor failed and replaced
Mar 2015 98000 mi US $1600	Vibration worsening with time. 3rd trip to dealer to diagnose. Replaced all 3 motor mounts. Runs like new.
Oct 2015 104000 mi US $350	Blower motor and temp sensor resistor replacement due to increasingly frequent loss of AC
May 2016 105000 mi US $300	Intermittent A/C. Found to be a loose wire connector. Problem returned within 48hrs
Jun 2016 105000 mi US $297	Loose connection in harness/connector causing interment blower operation, problem still agree acted by bumps.
Sep 2016 112000 mi	Intermittent AC blower operation.
Mar 2017 122000 mi US $400	AC blows intermittent , shuts down, then blows again for 15sec to 2min. Replace AC temp sensor . Replace motor mounts, second time in 3years
May 2017 126000 mi	AC blower low output, warm air. Replace cabin air filter, replace blower motor (warranty)

Ford Fusion in Michigan, United States Jul 2010 - Apr 2017
May 2012 29700 mi	rear tail lamp burnt out.
Feb 2013 37100 mi	Trunk seal was coming off the flange and had to be re-glued under warranty.
Aug 2014 42000 mi	Airbag light was on intermittently due to a pinched/damaged wire.
Feb 2016 62700 mi US $50	Airbag light turned due to short. Replaced wire harness
Nov 2016 72100 mi US $50	Airbag warning light on.

Ford Fusion in California, United States Dec 2009 - Mar 2018
Jun 2010 4000 mi	a. Very slight drift to the right - tires rotated and balanced. No more problems b. Rubber seal on back window was loose - repaired successfully by dealer
Jun 2013 25000 mi US $49	Moonroof became unseated. Dealer cleaned tracks and lubed. Fixed!
Dec 2013 30000 mi US $100	Drive side interior door handle broke. Replaced. (Seems to be a common problem).
Jan 2014 56200 mi US $101	Battery wouldn't hold charge. This is the second battery I have had to replace. Next time I won't go to the dealers' for battery.
Nov 2015 49000 mi US $450	Compass display always at North. New module ordered and installed.
Jul 2016 56300 mi US $168	Driver's door handle failed (2nd time). These are very cheaply made and apparently fail often.
Dec 2016 61000 mi US $1080	Leak in steering/AC condenser - unit replaced

Ford Fusion in Illinois, United States Jul 2014 - Jun 2018
Feb 2016 88600 mi US $1000	Rear caliper guide pins had corroded causing the pads not to release and drag against the rotor causing extreme premature wear. Had to replace rotors and pads again. Battery was not holding a charge. Battery was brand new when I bought car, however the dealer installed a under powered battery when I bought it causing it to fail after two and a half years. Installed newer more powerful battery. Driver heated seat element burned out. Replaced heating element under extended warranty
Jul 2016 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.
Apr 2018 116000 mi	Uneven tire wear and minor steering wheel shake

Ford Fusion in Arizona, United States Dec 2009 - Sep 2012
Dec 2010 27000 mi	Spring holding door over gas filler tube came loose and had to be replaced. Door would stay shut but not self-close.
Feb 2011 29000 mi	Battery would not hold charge (replaced) and stablilty control module also replaced (worked fine until battery died - don't know which caused which)
Aug 2012 58000 mi US $275	Rear interior door handle broke

Ford Fusion in Quebec, Canada Feb 2010 - Aug 2013
Feb 2011 14880 mi	Noise from front vent. Diagnosed as "door actuator" problem. Part ordered.
Mar 2011 15500 mi	Ordered vent actuator was installed.
Jun 2012 28520 mi	Backup camera intermittently not working. They were unable to diagnose the problem as it worked while they had the car. It has not failed again since then.
Dec 2012 32860 mi	Passenger airbag sensor was malfunctioning. It was replaced.
Feb 2013 34260 mi C $50	Battery would not hold a charge. It was replaced.

Ford Fusion in West Virginia, United States Apr 2009 - Sep 2011
Feb 2011 18000 mi	Low tire pressure sensor had to be replace when the light on the dash continuously said I had a low tire
Jun 2011 21000 mi US $10	Tire pressure light on with no tire pressure problems. Engine surging--fixed due to TSB
Sep 2011 21000 mi US $100	Interior door handle on the driver's side broke, making it impossible to get out of car. Part was ordered and door fixed

Ford Fusion in Maryland, United States Oct 2009 - Nov 2012
Nov 2009 1000 mi	Car stalled while driving, the battery and oil indicators were the only two lights on. Checked both battery and oil - no problems. Set up appointment with dealer. Problem not duplicated. checked Ford forums - same issue with multiple models.

Ford Fusion in Ontario, Canada Nov 2011 - Jul 2012
Dec 2011 44640 mi	bad automatic driver window mechanism (would make weird noise) motor and assembly replaced by the dealer Sc button on the center stack console was pealing off. Dealer replaced the entire center stack console
Jan 2012 45340 mi	Rattles coming for the dashboard. It took 3 trips to the dealer in order to get most of them out. A kit was installed by the dealer. Most of the rattles are fixed although once in a while I hear them. Driver seat and arm rest squeaks. After the third trip to the dealer got the issues resolved as the dealer lubricated the seat and arm rest.
Jun 2012 52080 mi C $455	Throttle body control unit went bad on HWY and although I still had powertrain warranty it is not covered.

Ford Fusion in California, United States Sep 2014 - Oct 2014
Oct 2014 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.

Ford Fusion in South Dakota, United States Oct 2016 - Mar 2018
Dec 2016 95000 mi US $55	Replaced Oxygen sensor after check engine light came on

Ford Fusion in Georgia, United States Nov 2009 - Jun 2011
Dec 2009 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. Engine would hesitate and feel like it was going to stall out. tach would drop air conditioning would freeze up and not work. Fix not yet verified.
Feb 2010 11000 mi	I finally agreed to allow Ford to install yet another transmission. This one at least appears to have resolved the issue.
Mar 2010 11000 mi	Replaced SYNC module. The car shut off while driving. Yes, this car simply shut off while driving in a school parking lot. Once it shut down it would not start. Needed to be towed. 2010 Ford Fusion is junk and now unsafe.
Jul 2010 18000 mi	The transmission slammed into reverse. I have had and apparently continue to have problems with my transmission.

Ford Fusion in Texas, United States Feb 2010 - Feb 2015
Apr 2012 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.
May 2013 22000 mi US $100	Problem with car going into limp mode. Concerned it was linked to previous transmission issue. Replaced throttle body and sensor.

Ford Fusion in New Jersey, United States May 2010 - Jun 2014
Jun 2014 112000 mi US $505	AC not working. Front passenger door latch not working. Latch replaced.

Ford Fusion in Florida, United States Oct 2012 - Jun 2018
May 2013 22400 mi US $89	hard shifting, re programmed software.
Jun 2018 54000 mi US $450	The positive battery cable was corroded and needed to be replaced so I could replace the battery as well. Turned out the positive cable was actually one of the main wiring harnesses and had a book time of 3 hours to replace. This was a real shocker. On most well-designed vehicles the cable is a single cable going to the starter VERY POOR DESIGN

Ford Fusion in Ontario, Canada Aug 2009 - Dec 2015
Feb 2011 31620 mi	The blower motor was squeaking loudly. Dealer ordered a new blower motor, and replaced the noisy blower motor a week later when the part came in.
Mar 2013 75020 mi C $150	I replaced a squeaky blower motor.  An emissions purge valve had to be replaced. I was able to do the work myself.
Dec 2013 90520 mi C $150	Battery would not hold a charge, had died a few times in the past but a jump start seemed to fix it but just wouldn't hold a charge anymore, so had it replaced at independent shop.
Dec 2014 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.
Feb 2015 113460 mi C $80	Had to replace the windshield washer jets as the hoses connecting to the jets cracked and broke leaking washer fluid onto the engine.

Ford Fusion in Indiana, United States Sep 2009 - Dec 2012
Mar 2010 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.
Apr 2010 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.
Aug 2010 18000 mi	Transmission is still acting up, hasn't been right since 1-2010, dealer cannot fix it. fuel door spring broke, fuel door was replaced under warranty.
Sep 2010 19000 mi	Car is a lemon - faulty transmission since January 2010
Dec 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.
Mar 2011 26000 mi	Transmission whining, very obvious and everyone BUT Ford dealer acknowledges it.
Jun 2011 32000 mi	Transmission failing to shift on highway. Severe slipping and banging. Failure to reset to 1st gear at stops when coming off highway
May 2012 42700 mi US $140	Car was stalling out from rolling starts or coasting such as crossing railroad tracks!!! Dealer diagnosed as throttle body, and I fixed it myself in 5 minutes due to out of warranty. New seems to have helped transmission slipping/bucking.
Jul 2012 43500 mi	A/C is out at 43,000 miles, there is a leak in a line and will cost too much to repair. Car is out of warranty...
Dec 2012 46000 mi	Car had issue starting after sitting around without being used. Would barely turn over then sputter to life and knock real loud. AC out.

Ford Fusion in Maryland, United States Jul 2013 - Jan 2022
Aug 2013 53000 mi	Driving down the highway the car went into Limp Mode. Turns out the Throttle Body had to be replaced.
Jan 2015 US $150	Passenger side mirror became unglued.
Mar 2015 73000 mi US $200	Check Engine Light. Required to replace fuel filler tube and reprogram PCM. Known issue via Published TSB. Recall to recalibrate Throttle Body Sensor.
Dec 2016 96000 mi	EGR Valve and canister recall

Ford Fusion in Maryland, United States Dec 2013 - Oct 2016
Feb 2014 29300 mi	Replaced rear seal transmission
Sep 2015 38000 mi	Black and burned transmission fluid requiring flushing

Ford Fusion in Pennsylvania, United States Jan 2017 - Nov 2017
Nov 2017 89000 mi US $400	replace fuel evap valve and cannister...2nd replacement since having the car...

Ford Fusion in California, United States Sep 2009 - Jun 2022
Apr 2011 15300 mi	Replaced weather stripping that was improperly installed from factory causing it to crack. Replaced leaking master cylinder cap. Replaced trim piece in steering wheel that controlled volume, radio selection, etc. Part worked but was loose due to broken connector. Replaced keypad on drivers door due to one of the 5 keys being dim.
Jan 2012 14200 mi	Replace valve cover gasket.
Jul 2012 27000 mi	Replace blower motor due to chirping sound.
Aug 2012 28300 mi	Broken piece on moon roof prevented it from closing properly. Broken trim piece on driver's seat.
Oct 2012 30000 mi	Lose trim piece on steering wheel.
May 2013 37100 mi US $100	Battery would not charge, replaced.
Aug 2013 38400 mi US $150	Car went into fail safe mode on highway. Bought new throttle body on amazon and replaced it myself.
Nov 2013 41700 mi US $23	Replaced backup warning speaker. Old speaker made high pitch sound instead of normal sound. Bought off of ebay.
May 2014 47400 mi US $200	Replaced leaking AC hose from compressor to condensor. Recharged system.
Sep 2014 51000 mi	Replace valve cover gaskets and grommets due to them leaking oil.
Nov 2014 52000 mi	Engine was still leaking oil after replacing valve cover gasket. Oil leak found by front cover, crankshaft seal and valve cover gaskets/grommets were replaced.
Sep 2015 59000 mi US $80	Car made grinding noise when turning right. Replaced the driver's side CV axle myself (after watching YouTube video).
Nov 2015 61000 mi US $125	Car was making harsh almost grinding noise when accelerating in low gear. Notice upper engine mount was leaking. Replaced it myself after watching Youtube video (wasn't too hard, but need jack and breaker bar). Car runs great now.
Aug 2017 81000 mi	Purge solenoid replaced under recall.
Jun 2018 86000 mi US $25	Axle seal on drivers side appeared to be leaking, replaced it myself. Apparently this is a common problem.

Ford Fusion in New York, United States Apr 2010 - Jul 2020
Jun 2010 6000 mi	Automatic transmissiion slippage, early shifting. hesitant shifting, erratic shifting
Jul 2012 20000 mi	Throttle body failed. Car would not respond to accelerator depression. Throttle body was replaced.
Sep 2013 30000 mi US $166	Faulty tire pressure sensor.
Dec 2013 32000 mi US $290	Parking brake lever was stuck in the engaged position. It was determined that the release button/cable was at fault. The entire mechanism is one unit so the whole thing had to be replaced.
Sep 2014 38000 mi	The car was in for routine maintenance & I was told the cabin filter needed to be replaced.
Oct 2017 60000 mi US $3	Replaced rear turn signal bulb. It took much longer than ten minutes. I had to remove much of the inner lining of the trunk just to get to the tail lamp.
Jun 2018 66000 mi US $725	Valve cover gasket leak. Replaced two valve cover gaskets, six spark plug apertures, and six spark plugs.
May 2019 72000 mi US $130	Sync system stopped working, no longer paired with cell phone. After four hours of attempting to reprogram the system, it was determined that the "module" needed to be replaced. Part was ordered but has not yet arrived.

Ford Fusion in North Carolina, United States Aug 2013 - Sep 2013
Sep 2013 55000 mi US $400	Car went dead on the highway with no warning. Took them several hours to diagnose the issue but ended up replacing the throttle body.

Ford Fusion in California, United States Apr 2011 - Aug 2012
Nov 2011 15700 mi	Sudden loss of throttle control and power, engine and trabsmission went into failsafe/limp mode. Service engine light on, code indicated throttle body unit failure. TB was replaced. Acceleration from rest and shifting now much smoother

Ford Fusion in Montana, United States Aug 2013 - Dec 2013
Sep 2013 128000 mi US $460	O2 sensor failure code, replaced part 3 times so far and every component in this subsystem. Still coding and check engine light remains on.

Ford Fusion in New Hampshire, United States Oct 2014 - Dec 2015
Sep 2015 80000 mi US $237	Had to re-flash the transmission due to rough shifting.
Nov 2015 80000 mi	Battery would be flat unless run at least every two days. Charging system, battery, etc. checked OK by dealer. Dealer wanted $100 min to check further, which I refused. Traded car elsewhere.

Ford Fusion in Ontario, Canada Dec 2009 - Jun 2011
Mar 2010 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.

Ford Fusion in California, United States Jan 2017 - Jul 2018
Jul 2018 52999 mi US $2080	Engine would miss at all speeds and particularly uphill. Spark plugs and coil replaced.

Ford Fusion in Connecticut, United States Jul 2009 - Jun 2013
Sep 2010 33000 mi	Sunroof leak - dealer replaced glass at no charge. Check transmission valves and reflash TCM
Dec 2011 59000 mi	Check Engine Light and Code revealed problem with Variable Cam Timing (VCT). Dealer replaced solenoids in VCT under warranty.

Ford Fusion in Pennsylvania, United States Jun 2017 - Jun 2018
Jun 2018 68000 mi US $300	Parking brake froze during the winter and prematurely wore out the brakes.

Ford Fusion in Texas, United States May 2018 - Aug 2018
Jul 2018 126000 mi US $650	Replacement of motor mount
Aug 2018 128000 mi US $800	Replace brake caliper and rotor, consequently master cylinder brake.

Ford Fusion in Ontario, Canada Jun 2009 - Jan 2017
Oct 2013 64460 mi C $800	Bearings in the idler and other pulleys worn out.

Ford Fusion in Minnesota, United States Jun 2009 - Mar 2012
Aug 2009 5000 mi	Wheel covers damaged by an improper installation by the dealer after the first scheduled oil change and tire rotation. Two wheel covers were lost, the two remaining were damaged. Was told parts from problem had arrived. Showed up to our scheduled appointment to find that they were not in fact in stock and even more upsetting, had not been ordered. Scheduled another return trip. New wheel covers had been ordered and were replaced.
Dec 2010 31000 mi	Noticed a rattle from engine bay during startup and at clutch engagement point in 1st and reverse. Tech road tested and found airbox had become unseated from pressure fit mount. Tech reseated airbox. Hopefully it does not return.

Ford Fusion in Ontario, Canada Apr 2010 - Feb 2022
Mar 2014 66340 mi	Loose windshield wiper arm.
May 2014 68200 mi C $250	CEL code for evap sensor triggered. Sensor itself was defective and replaced.
Mar 2017 112840 mi C $450	Pothole damaged front passenger? wheel bearing and tire
Jul 2017 119040 mi C $480	Rear driver wheel bearing noisy, found to be damaged and had to be replaced.
Mar 2018 128960 mi C $700	Parking brake caliper, pad and cable replaced.
Sep 2021 168640 mi C $200	Leaky gasket, gasket replaced.

Ford Fusion in Georgia, United States Jul 2009 - Mar 2016
Aug 2009 1000 mi	front turn signals did not work, smart junction box replaced
Dec 2011 30000 mi	grab handle passenger side replaced
Apr 2012 36000 mi	battery not holding charge, replaced buzz in left speaker when engine on during usb
Jun 2013 55000 mi US $37	car bucking during acceleration after manual shift completed. No codes or check engine light. shop cleaned throttle body sensor. This did not help, rechecked, decided to replace sensor. Waiting for part, unavailable for 4 weeks.
Jul 2013 55700 mi US $300	Follow up to June report: after 4 weeks, throttle control unit became available. Part=$200, labor=$100. repair complete
Aug 2013 56000 mi US $50	Follow up to previous repairs. Still hesitating, swapped out other sensors to no avail. Finally found that the wiring pigtail connector Motorcraft WPT1241 was under strain and many of the wires were fraying. New harness has strain relief.
May 2014 72000 mi	Tire pressure sensor fault, light on dash. Tires fine. Mechanic said battery in the tp sensor might be bad and that the other batteries might go out. Repair seemed too costly at this time.
Jun 2014 76000 mi US $100	TMPS sensor went out and was replace when new tires purchased. Fuel fill inlet warning/check engine light ton. Mechanic checked systems found no problem. reset warnings. Warning on and then gone 2 more times. car shows no symptoms
May 2015 89000 mi US $207	interior driver and passenger door handles broke
Mar 2016 97000 mi US $200	serpentine belt tensioner

Ford Fusion in Florida, United States Jul 2009 - Feb 2014
Sep 2009 1000 mi	Intermittent no start. Engine turns over but will not start. Dealer pull codes and none were found. Dealer could not replicate the problem. 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.
Oct 2009 2000 mi	Clutch needed adjustment after the transmission was replaced earlier in September. No start, issue unresolved.
Jan 2010 5000 mi	No start or Hard start. Extra ground strap with a capacitor added per TSB.
Mar 2010 10000 mi	Drivers inside door handle broke.
Jul 2010 16000 mi	Whining noise coming from engine. Whining noise increased and decreased with engine RPM. Belt Tensioner Pulley replaced.
Jun 2011 30000 mi	Smell from AC. System deodorized and fan replaced.
Aug 2011 32300 mi	Grinding gears when shifting from 1st to second at high rpms.
Jan 2012 39000 mi	Occasional grinding shift from 1st to 2nd gear
Apr 2013 56300 mi US $347	Throttle Body replaced.

Ford Fusion in Ontario, Canada Dec 2009 - Mar 2020
Dec 2017 114080 mi C $700	tie rods
Jan 2018 114700 mi C $500	Throttle body reaplacement

Ford Fusion in Indiana, United States Oct 2009 - Apr 2017
Jan 2010 5000 mi	Air trapped in the cooling system causes a fluid swishing sound as car is accelerated when cold or engine idling for 1 minute or more. Occurs less frequently when at operating temperature. Still exhibiting the sound of coolant flowing through the heater core. Ford is providing the dealer with another procedure to attempt a fix. Car will be at dealer during the week of February 8, 2010. Air trapped in the cooling system causes a fluid swishing sound as car is accelerated when cold or engine idling for 1 minute or more. Occurs less frequently when at operating temperature. Still exhibiting the sound of coolant flowing through the heater core. Ford is providing the dealer with another procedure to attempt a fix. Car will be at dealer during the week of February 8, 2010.
Mar 2010 6000 mi	Dealer contacted Ford on air trapped in cooling system. Dealer ran tests as requested by Ford. Ford sent field engineers to evaluate car and recommended complete engine replacement. Since repair, coolant sound is no longer present. TSB 09-19-1 to correct intermittent/no start done. No problem starting since completed. Dealer contacted Ford on air trapped in cooling system. Dealer ran tests as requested by Ford. Ford sent field engineers to evaluate car and recommended complete engine replacement. Since repair, coolant sound is no longer present. TSB 09-19-1 to correct intermittent/no start done. No problem starting since completed
Jun 2010 12000 mi	Sync system required a system download so that the USB port and phone would operate. Took 40 minutes for the two downloads. No problems since the work. Sync system required a system download so that the USB port and phone would operate. Took 40 minutes for the two downloads. No problems since the work.
Jun 2011 32000 mi US $180	Driver's side inside door handle mechanism jammed and door handle cracked. Part ordered and replaced. Car was in for routine maintenance. Mechanic noticed right rear brake pad was almost completely worn out. The suspected cause was the caliper was not sliding freely. the slides were lubricated on reassembly. Unusual problem for only 32K.
Jul 2011 33900 mi	Air coming from ducts would stop even though fan blower was working after a couple of hours on the highway. Took car in for TSB on AC problem. Reflashed the AC programming. Seems to be working normally now. AC stops blowing cold air after extended highway driving. AC system reflashed according to TSB. No problems since then.
Nov 2013 78200 mi US $280	Alternator voltage regulator failed and would not keep the battery charged. Serpentine belt changed during alternator replacement.
Sep 2014 93000 mi US $130	Battery would loose a charge with little electrical load if engine wasn't running. Battery was 66 months old and the original factory battery.
Sep 2015 109000 mi US $140	After a dead battery, the wrench light would come on and the engine would not go above 900 RPM. Tried the relearning process for the throttle body but it didn't work. Replace throttle body and did the relearn process. It fixed the issue.

Ford Fusion in British Columbia, Canada May 2016 - Jun 2018
Aug 2016 43400 mi	check engine light on,evap code
Nov 2017 68200 mi C $50	REPLACED EVAP PURGE SOLENOID

Ford Fusion in Quebec, Canada May 2012 - Aug 2013
Jan 2012 23560 mi C $50	Changing the fuse of the 12 volt plug.
Apr 2013 38440 mi C $233	Changing the vapor valve

Ford Fusion in New Jersey, United States Sep 2010 - Jul 2012
Jul 2012 35000 mi	Complete replace of transmission

Ford Fusion in Virginia, United States Mar 2011 - May 2015
May 2015 77000 mi US $15	Sync and Parking sensor speaker replaced.

Ford Fusion in California, United States Dec 2017 - Jun 2018
May 2018 120000 mi US $55	Airbag light on. Connections were checked, one was loose. Oil change.

Ford Fusion in South Dakota, United States Mar 2010 - Jan 2022
Aug 2010 28000 mi	One Touch Ignition would not start car, needed new ground wire per TSB
Apr 2011 46400 mi	Axle Seal Leak, seal and other other components replaced per TSB. Transmission Fluid Replaced. Replaced leaking axle seal as instructed by TSB
Jun 2014 114000 mi US $120	Worn o-rings on compressor were leaking coolant.
Jun 2015 136000 mi US $50	Broken driver side door handle
Oct 2016 166500 mi US $250	Squeaky serpentine belt
Apr 2017 175000 mi US $25	Ground wire to headlights needed replaced
Mar 2018 193000 mi US $66	Belt tensioner replacement
Apr 2021 238000 mi US $60	Head gasket replaced

Ford Fusion in Texas, United States Feb 2011 - Dec 2011
Jul 2011 38000 mi US $500	Engine would not start after towing. Dealer said it was towed in gear. Transmission burned up. New one on order.
Nov 2011 40000 mi	Battery still has to be jumped after towing 4 wheels down. car cannot start if left in neutral and key left in accessory for a short period of time. Dealer say they don't know why. They tried it on a new Fusion and the same thing happened.

Ford Fusion in South Carolina, United States Apr 2012 - Apr 2012
Apr 2012 40000 mi	SYNC System reset

Ford Fusion in North Carolina, United States Jul 2011 - Jun 2022
Feb 2015 105700 mi US $700	Warning Light for emissions system - catalytic carbon filter

Ford Fusion in Virginia, United States Mar 2011 - Dec 2015
Jun 2013 27000 mi	The transmission was shifting from 3 to 4 harshly. The dealer reprogrammed the automatic transmission and that seems to have worked. The rubber strip at the bottom of the window kept failing off and the glue did not stick well and was always getting on things.
Oct 2013 29700 mi US $576	Check engine light came on. Shop smoke tested system and reported EGR valve was leaking. Replaced EGR valve.
Mar 2015 45000 mi US $350	I had a coolant leak. They replaced the adapter that bolts to the back of the engine. In this case back is the opposite side from the pulleys or the drivers side of the block when looking under the hood.

Ford Fusion in Massachusetts, United States Nov 2011 - Oct 2018
Jan 2013 70000 mi US $200	EVAP solenoid was bad
Oct 2014 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
Feb 2015 100400 mi US $400	Transmission leak found. Replaced drivers axle seal
Sep 2016 139000 mi US $1100	Front spring cracked. Replaced both springs and struts Exhaust flex pipe rusted out.
Feb 2017 154000 mi US $750	Fuel smell in cabin while idling. Dealer found a spark plug loose. Also replaced valve cover, and a solenoid.
Sep 2018 188000 mi US $500	Transmission cooler lines were leaking

Ford Fusion in Florida, United States Nov 2012 - Mar 2014
Mar 2014 60000 mi US $100	the throttle body went bad At 45k miles, February 2013 the seat heater fried out and got really hot burnt the seat. Never repaired.

Ford Fusion in Colorado, United States Dec 2011 - Apr 2015
Dec 2014 134000 mi US $300	Engine and Transmission mounts were broken which caused grinding noise when accelerating. Parts replaced.

Ford Fusion in Kentucky, United States Jul 2015 - Jun 2018
May 2018 172000 mi US $65	Head light

Ford Fusion in Manitoba, Canada - Nov 2009
Nov 2009 2170 mi	TSB to replace engine ground strap

Ford Fusion in New York, United States Sep 2013 - Jul 2022
Apr 2015 128300 mi US $10	Driver side bushing and seal replaced..Was leaking trans fluid....
Oct 2016 137500 mi US $40	replaced both outer tierods
Aug 2017 145000 mi US $150	Replaced rear rotors ,calipers and brakes
Feb 2018 148000 mi US $36	Driver side interior door handle replaced...

Ford Fusion in Michigan, United States Jun 2013 - Jan 2016
Sep 2015 89000 mi US $320	left rear pads wore out in one year, replaced defective caliper and installed new rotors

Ford Fusion in New York, United States Jan 2015 - Dec 2016
Jan 2015 56000 mi US $32	Car was throwing P0456 code. Internet search revealed common problems with the purge control vent valve. I tested my vent valve. It was faulty. Test took 10 minutes. Repair took 10 minutes once part had arrived.

Ford Fusion in Ontario, Canada Jan 2011 - Sep 2017
Aug 2012 61740 mi	Inside door handle broke
Dec 2012 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.
Feb 2014 93360 mi C $200	belt tensioner replaced
Aug 2015 126480 mi C $58	door handle on driver side door, 2nd time. Dealer cost $200. did the repair myself for the cost of the part ($58).
Dec 2015 135780 mi C $785	fan belt replacement and damaged to part of air conditioning system. Disappointed dealer didn't recognize noise from worn out fan belt at previous oil change
Feb 2016 138580 mi C $200	tire pressure sensors not working
Oct 2016 154360 mi C $637	front and rear brake pads rotars calipers replace both outer tie rods

Ford Fusion in Connecticut, United States Mar 2014 - Jul 2022
Aug 2015 21600 mi US $100	Faulty Water Pump. Covered under warranty
Aug 2016 25000 mi US $120	fuel vapor vent valve
Feb 2018 32000 mi	Battery was run down. Dealer checked it and said it was OK - did not need replacement.
Oct 2021 32000 mi US $50	Tires leaked - dealer unmounted tires and cleaned up corrosion on wheel/tire bead interface

Ford Fusion in Virginia, United States Jun 2015 - Jun 2016
May 2016 47600 mi US $110	Began with oxygen sensor, ended up with computer replacement.

Ford Fusion in Iowa, United States Mar 2017 - Jun 2018
Oct 2017 130000 mi	Front and rear rotors and pads. Rear pads were shot. Replaced spark plugs purely due to mileage. The old plugs looked great, probably could have done another 50,000 miles!

Ford Fusion in Ontario, Canada Dec 2011 - Jun 2022
Dec 2017 130200 mi C $100	stuck emergency brake

Ford Fusion in North Carolina, United States Mar 2013 - Dec 2013
Apr 2013 48300 mi	Car was whining when accelerating. Alternator pulley.
Dec 2013 57000 mi US $60	HVAC fan was squeaking like a bird. 5min, $60, 3 screws and one plug and I put a new one in. Super easy so don't pay someone to do it. Seems to be a common problem

Ford Fusion in Newfoundland / Lab., Canada Jan 2012 - Sep 2021
Nov 2012 19780 mi	back passenger caliper became stuck and needed replacement along with pads and rotor.
May 2013 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.
Mar 2014 35340 mi C $60	Window wipers stopped working. dealer disassembled and inspected motor and got them working. Ice build-up was the cause
Jun 2015 45880 mi C $160	Serpentine belt was worn and needed replacing. Replaced by backyard mechanic using an AC Delco belt
May 2017 57660 mi C $200	Cracked spring on left front. Replaced whole strut/spring assembly for ease of repair and cost.
Jan 2018 64480 mi C $100	Car was not shifting properly. Getting stuck in 1st, 2nd. Trans fluid was black and slightly low. Trans fluid replacement fixed issue.
Jul 2018 68200 mi C $1250	Electric steering rack failed, needed replacement.

Ford Fusion in Texas, United States Feb 2015 - Dec 2016
Oct 2016 51000 mi	Throttle body malfunction. It was replaced under recall warranty.

Ford Fusion in Michigan, United States Feb 2018 - Mar 2018
Mar 2018 62000 mi US $50	Trans fluid change, oil changel

Ford Fusion in South Dakota, United States Oct 2013 - Nov 2013

Nov 2013 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.

Ford Fusion in Oklahoma, United States Sep 2013 - Sep 2013
Sep 2013 80000 mi US $225	I got both OBD II codes P2011 and P2012, but not at the same time. It was either one or the other code showing. I did some research, and found out that I needed to replace the throttle body. Since the throttle body replacement no codes.

Ford Fusion in Washington, United States Dec 2012 - Jun 2018
May 2014 37000 mi US $210	Engine check light. Dealer said error was for transmission and firmware update fixed it. Battery test failed. Battery was replaced
Oct 2014 40300 mi US $100	Parking brake switch. Switch had been triggering a "Packing brake engaged" warning when parking brake was actually released, disabling cruise. Engine check light. Vapor valve was found defective
Sep 2016 57000 mi	Fuel tank leak
Sep 2017 68000 mi US $1000	Driver's seat replacement due to a heating element failure
Dec 2017 70500 mi US $50	Driver's door handle broke

Ford Fusion in Ohio, United States Oct 2010 - Jun 2021
Jun 2014 47000 mi US $75	Electric window on drivers door malfunction. Computer module reset required.

Ford Fusion in Pennsylvania, United States Nov 2009 - Jun 2015
Dec 2013 48000 mi US $250	Faulty purge valve caused "Check Engine" light to go on. Brought to dealer for diagnosis and repair. Exhaust system had a faulty sensor.

Ford Fusion in Minnesota, United States Nov 2009 - Mar 2010
Dec 2009 8000 mi	Starting difficulty--car would at times crank 3-4 times before turning over. Problem is with an electrical short connected with the car's starter--solved by installing a "ground strap." Ground strap installed.
Jan 2010 10000 mi	Complete transmission replacement; covered under warranty.

Ford Fusion in New Jersey, United States Oct 2009 - Dec 2017
Apr 2011 32000 mi	no cold air
Dec 2011 46000 mi US $98	new battery purchased at 45,000- very early failure i have since disabled the feature that keeps headlight on when starting and leaving the auto. also disabled some of the cabin overhead lites to reduce load on battery.
Feb 2013 60000 mi	replace smooth idler pulley and belt tensioner because of noise
Oct 2014 87800 mi	Engine quit on busy road. Was able to restart.Fault was throttle control system failure.
Sep 2015 110000 mi US $100	worn upper right side motor mount causing a noise on pulling out. Note: deka (penn) battery installed at 40k holding up. Note: use care when parking that your front bumper does not get ripped off by rebar on the parking blocks.
Apr 2016 120300 mi US $100	Upper motor mount replaced.
Jul 2016 122000 mi US $1200	Dash was pulled to replace defective air conditioner sensor $800.00 Rear brake pad was hung up causing wear. Declined this repair because i only want my own mechanic to do brake work. THESE SMALL PADS are a ripoff. Thanks Ford. My mech had to use special tools to remove the frozen damaged lug nuts that Bevis/But-head did to my car. Dealership said damage was due to old age of lug nuts.!!!!!!!!!!!!! Talked to customer service rep in Detroit. Would have most likely had to be towed at great expense had i found out about this on the road.
Sep 2016 123000 mi US $120	LUCAS TRANS-FIX Worked -----Lower motor mount replaced. Still had loud noise when shifting at high speed and found that it was due to 6F35 transmission. Lucas transmission fix was added and after 3 weeks the noise was gone.
Apr 2017 130000 mi US $200	Tire pressure sensors replaced. Ordered VDO sensors from Rock Auto and had my mech install.

Ford Fusion in New Jersey, United States Oct 2009 - Oct 2012
May 2010 5200 mi	I had the service light go off for the traction control. It did not stay on for long, but I took it in for them to look at. They saw the alert on their computer but did not see a problem.
Feb 2012 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.
Jun 2012 25000 mi	My driver's side visor kept popping out. Under warranty, they replaced the visor and its clip. Engine makes rattling/whirring noise at 35 & 45 mph. Took two drives for servicemen to hear it. Because computer did not detect problem, nothing broke, no repair made. It is a standard noise heard on their rental cars - no problem. WHAT?!
Sep 2012 27150 mi	I took it AGAIN for whining engine at 35&45 mph & getting louder. Took 2 drives for them to hear. First they said "Normal noise" but I said it was NOT normal. They worked w/ Engineers and replaced pulley/tensioner. ALL GONE! Under warranty After only 9 days back from the shop, my car emergency engine lite went on & engine vibrated, even in Park. After tow to shop, svce says it was a bad throttle body, like many Ford Fusions. Was replaced with brand new one under warranty. I took it AGAIN for whining engine at 35&45 mph & getting louder. Took 2 drives for them to hear. First they said "Normal noise" but I said it was NOT normal. They worked w/ Engineers and replaced pulley/tensioner. ALL GONE! Under warranty After only 9 days back from the shop, my car emergency engine lite went on & engine vibrated, even in Park. After tow to shop, svce says it was a bad throttle body, like many Ford Fusions. Was replaced with brand new one under warranty.

Ford Fusion in New York, United States Jan 2009 - Jan 2017
Dec 2009 8000 mi	Had a starting problem. There is a campaign on this, and it involved adding a new ground.
Feb 2011 24000 mi	A spray shield under the engine came loose and was dragging on the ground. The dealer reattached it for free under warranty.
Mar 2013 49000 mi US $50	I put new gas springs on the trunk lid
Jun 2013 51000 mi	Occasional "flare" (momentary increase in rpms as if missing a shift with a std. trans.). This didn't happen very often though.
Mar 2014 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. Steering wheel controls for phone, etc. not working. Module part was over $800, and total bill about $920.
Jul 2014 63200 mi	engine noise, actually a tensioning pulley on the serpentine belt
Nov 2015 74100 mi	Alloy wheels had corroded so tires had slow leaks.

Ford Fusion in New York, United States Jan 2010 - Jun 2012
Jun 2012 24000 mi	idler arm pulley had to be replaced

Ford Fusion in California, United States May 2010 - May 2013
Jul 2012 34000 mi	Recirculation motor chirping. Removed/replaced.

Ford Fusion in Massachusetts, United States Mar 2010 - Dec 2017
May 2010 2000 mi	scratch on fender
Jan 2014 50000 mi	driver side seat heater stopped working after extremely hot temp,have not repaired yet
Feb 2014 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
Nov 2015 77000 mi US $50	drivers power window stopped half way down
Jan 2017 56800 mi	Radio sync cd stop working intermittently

Ford Fusion in Minnesota, United States Feb 2011 - Jul 2018
May 2011 35800 mi US $40	driver's seat made clicking noise when driver moved leg - bad spring, replaced seat
Jul 2012 57000 mi US $100	Speed control problem; no acceleration - throttle body control unit was replaced.
Jun 2013 68000 mi US $237	system was freezing up. found there was TOO MUCH refrigerant in system and bled off 3 lbs.
Jul 2018 147000 mi US $993	Replaced wheel bearings on both sides

Ford Fusion in Ontario, Canada Jun 2009 - Jun 2011
Nov 2009 4340 mi	Car would not start on first or second try. However, this was an intermittent problem that would happen about once per week so hard for mechanic to determine the problem. Installed grounding wire.
Jan 2010 5240 mi	When engine first started (after being off for more than 60 min or so) there's a noise like a surge of water through an empty pipe. Dealer says Ford knows of the problem and is trying to find a solution. Told it's a problem reported by many Fusion owners.
Apr 2010 7440 mi	Low tire pressure warning saying "TIRE SENSOR FAULT". No reason given but problem fixed by re-set of software I was told.
Jun 2010 9300 mi	We noticed jerky shift. Friend said they had a recall notice but we did not get one. When car went to dealer they adimtted there was a recall. Transmission re-programed they said. Seems OK so far but haven't driven much since repair.

Ford Fusion in Michigan, United States Aug 2009 - Jun 2016
Oct 2009 1900 mi	TSB performed to correct transmission "flaring" when cold. TSB installed to correct transmission "flairing" when cold. TSB was successful.
Nov 2009 2900 mi	TSB performed to correct occasional hard starting that seemed to occur only when raining or very humid. Added grounding wire. TSB installed to correct occasional hard starting that seemed to occur only when raining or very humid. TSB was successful.
Mar 2011 27000 mi	Serpentine belt idler wheel bearing going bad (noisy). Quickly replaced by the dealer.
Jun 2012 48000 mi US $600	Map sensor
Feb 2014 84700 mi US $325	Idler pulley bearing

Ford Fusion in Maryland, United States Sep 2009 - Jun 2018
Jul 2012 27500 mi US $200	Half of the cost was for replacing a tire pressure monitor. Half was for replacing an A/C blower that was starting to click.
May 2018 100000 mi US $2000	Brake bads replaced and caliper needed to be replaced, had to wait for them to get one.

Ford Fusion in North Carolina, United States Jun 2009 - Jul 2015
Aug 2013 32000 mi US $56	replaced factory battery as it would not hold a charge

Ford Fusion in Texas, United States Jul 2009 - Mar 2014
Jun 2011 34000 mi	harsh shifting, trouble finding the right gear
Dec 2011 42000 mi	Blower motor made chirping sounds. They replaced it, under my extended warranty for 100$. Continued Harsh Shifting/Skipping, lack of power

Ford Fusion in New York, United States Mar 2009 - Nov 2014
Jun 2010 11000 mi	reflash ECU to fix very hard shifting -- Ford 'customer service bulletin' (aka recall-light). Seems to shift much smoother now, and doesn't throw the car forward like it used to. TSB for intermittent hard-starting; ground strap ordered per TSB. From passenger side of car, on cold engine moving between 1st and 2nd gears, sounds like water rushing through empty pipes; seems to go away with warmer engine. Dealer did not repair, and told me to reschedule another appt. to try again...
Jan 2012 26000 mi	Front passenger blower fan was 'clicking'. Replaced part, still clicking... have to take it back in for another repair...
Jan 2014 30700 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.
Apr 2014 59000 mi US $100	Center console storage button broken - entire center module had to be replaced. Passenger side vent fan broken - had to be replaced. Trunk lifters broken - had to be replaced Trunk would not latch - trunk latch replaced.

Ford Fusion in Kansas, United States Sep 2009 - Jun 2012
Jun 2010 13000 mi	Dashboard had air bubbles in it. Dealer replaced entire dash. Software upgrade performed during regular oil change. Less than a week out of shop during acceleration the tachometer soared but the vehicle would not/could not engage in gear. Dealer said software update should have solved it. Didn't.
Oct 2011 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.

Ford Fusion in West Virginia, United States Sep 2009 - Aug 2016
Oct 2009 4000 mi	bad ground wire replaced with new type, problem on first cars built
Dec 2013 68000 mi	Pads, rotors, calipers
Jul 2015 78800 mi US $180	Recharge air and replace pully Motor on air conditioner vent
Dec 2015 84000 mi US $50	warning light on brake air pressure AC has now been taken to dealer to refresh computer. I found there was a technical notice and gave dealer number. They did a refresh for $130 and that seems to have resolved the problem. Door handle on driver side broke

Ford Fusion in Pennsylvania, United States Oct 2009 - Jun 2022
Sep 2011 12000 mi	Air conditioner became intermittent during a long trip. Turns out that the problem was known issue, and there was a TSB: A/C SYSTEM LOSES AIR FLOW/INOPERATIVE— TSB 09-18-11 They re-flashed the computer, and that fixed the problem.
Jul 2012 19000 mi	Driver side door lock malfunctioned. Keychain fob would unlock but not lock the door. Lock would not work from the inside. Outside key would lock and unlock the door. Took to dealer; they replaced the lock and inside handle under warranty.
Nov 2012 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.
Jul 2013 24200 mi US $325	Air conditioner was not working. Fuses, relays, refrigerant were fine. Dealer found a failed Evaporator Discharge Air Temperature Sensor; quoted $25 for part and $760 for labor. Screamed bloody murder at dealer and Ford, who covered 60%.
Feb 2014 30000 mi US $156	Noted a smell of burning brakes while driving. Rear-left caliper was locked. Took to mechanic, found both rear pads shot-replaced both. Nothing wrong could be found with the calipers; suspect the parking brake froze during cold weather.
Feb 2015 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."
May 2018 62000 mi US $1400	A/C sensor failed again. Cheap part, lots of labor to replace. Passenger-side coil spring failed while vehicle was parked, a few minutes after I drove it home. Mechanic replaced the coil spring and both front struts. This would have been very,very bad had it been 10 minutes earlier.
Sep 2018 64000 mi US $947	Replaced both tie-rod ends, + front discs and pads.

Ford Fusion in New Jersey, United States Oct 2009 - Jun 2012
Nov 2009 10000 mi	air bag light came on. Connector was making bad connection, connector was replaced.
Dec 2010 23000 mi	Blower motor fan in HVAC makes constant clicking like a baseball card in bicycle spokes. Mechanic discovered damaged fan blade. Parts ordered however the fan motor was on "National Backorder" until recently. Still waiting for parts.
Jul 2011 29000 mi	Interior door latch handle on drivers door broke/deformed

Ford Fusion in Indiana, United States Sep 2009 - Jun 2011
Apr 2010 16000 mi	Car in shop since 5 April. Delay in software and hardware parts for transmission. Hope to have car back NLT 10 May. Asking Ford for new car under lemon law.

Ford Fusion in Alberta, Canada Jun 2010 - Apr 2015
Mar 2011 17360 mi	Replaced chrome grille. Chrome was bubbled on two grill cross bars.
Jun 2013 59520 mi C $250	Car was dead one morning. Dealer load tested battery and was OK. Re did test after road test. Battery failed. New OEM Battery installed. Muffler was rubbing on the frame. Noise resonating inside the car. Dealer repaired muffler hanger.

Ford Fusion in Wisconsin, United States Feb 2010 - Jun 2014
Nov 2010 16000 mi	Harsh 2-3 upshift when cold. Had Recall 10B15 performed, was told there was a "glitch" with that software and dealer flashed PCM according to TSB 10-21-9.
Apr 2011 21000 mi	Took it in for harsh 2-3 shift and intermittent RPM flare between same shift. Was told could not duplicate.
May 2011 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.
Dec 2011 33000 mi	Intermittent 2-3 shift flare returned. Went on test drive with mechanic and reflashed PCM with latest software. So far, so good.

Ford Fusion in Ohio, United States Jun 2010 - Dec 2014
Jun 2012 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. Passenger airbag sensor under seat went bad - would not detect passenger and would disengage airbag. Passenger door speaker rattling Driver assist handle spring failing - returns approximately four times slower than the rest. Dashboard cargo cover misaligned Trunk not centered on body. Functions fine but appears off center. Came this way from factory.
Apr 2013 48000 mi	Battery died twice in a week with no obvious source of drain. Well within warranty. Had it replaced.
Nov 2014 83000 mi US $179	Washer fluid pump failed. Dealer replaced the entire fluid reservoir and pump assembly. Trunk struts failed after 70,000 miles. Dealer did not have replacement parts available. Was told there was a TSB on throttle software. They reflashed the system

Ford Fusion in Ontario, Canada Sep 2010 - Jan 2016
Mar 2011 18600 mi	Top bar of chrome grill developed a "bubble" approximately 3 inches wide. The entire grill was replaced under warranty. Auto-dim mirror activates at night but fails as vehicles approach. Eventually, I have to point it away to avoid blinding. The mirror passed all testing. The issue is solved by rotating the mirror upside down so the sensors are higher.
Nov 2013 44640 mi C $600	Check engine light & "check fuel fill inlet" warning began occurring. Key fob failed (lock/unlock/trunk/alarm
Dec 2014 55180 mi C $553	Battery replaced as it only tested at 102 Cold Cranking Amps. 500 is the expected standard Licence plate light bulb was burned out. Testing revealed the assembly was cracked and corroded and needed replacement

Ford Fusion in Ontario, Canada Aug 2010 - Jun 2011
Sep 2010 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

Ford Fusion in Newfoundland / Lab., Canada Jul 2010 - Jan 2016
Oct 2010 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. Sept 20 34590km Temperature guage up on "H" and then goes back down to normal when I stopped the car. Check coolant, it was very low. No check engine light luminated. Problem: hole in radiator. It takes 4 day to ship rad and fix it.
Jan 2013 68820 mi C $280	Pulleys for drive belts were humming. Upper and lower tensioner pulleys replaced.
Apr 2013 70560 mi C $160	Driver window would not go down. Cable for pulley system broke. Cable was replaced.
Aug 2013 73160 mi	Check engine light on and 'Check Fuel Fill Inlet' reading on gauge warning. EVAP leak code found and smoke test required to find leak.
May 2014 89900 mi	Fog light lenses on both passenger and driver side have fallen out due to corrosion.
Jul 2014 94860 mi	Recall for problem with throttle body.
Aug 2014 95960 mi C $275	Transmission lines were rusted and leaking in 2 location. New transmission lines installed.
Oct 2014 98860 mi C $300	Front brakes rotors and seized calipers.
Nov 2014 99820 mi C $2234	Lost power assist steering. 'Advance Trac' and 'Service Power Steering Now' lights on. Dealer replaced both rear TPS sensors in tires!! Power steering restored. 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.
Feb 2015 104740 mi C $250	Tension pulleys making noise. Needed to be replaced.
Mar 2015 105400 mi C $500	Both wheel bearings replaced Replaced front and back pads and rotors. Freed stuck calibers.
Nov 2015 120500 mi C $300	Both sides have tie rods with excessive play in them.
Jan 2016 127100 mi	Fog light lenses had fallen out due to corrosion.

Ford Fusion in Michigan, United States Nov 2010 - May 2016
Dec 2014 106000 mi US $119	Water pump replaced due to mechanical failure

Ford Fusion in Ontario, Canada Jun 2010 - Jun 2011
Dec 2010 28520 mi	Cd player not working

Ford Fusion in Michigan, United States Jul 2010 - Apr 2013
Sep 2012 35000 mi	Gas gauge started dropping suddenly. There was an issue in the evap system which was fixed.

Ford Fusion in Ontario, Canada Jul 2011 - Oct 2014
Aug 2011 8680 mi	The pistons in caliper of rear wheels don't retreat back to their original position after brake being applied. This resulted in wheels being seized if car park in hot(30 minutes) and wet(over night,rusted together) weather.
Jan 2014 31000 mi	transmission acting weird @below 5km/h in stop and go traffic when engine is hot.
Oct 2014 43400 mi C $333	engine light on. was told EVAC valve needed replace because some over spill gas go into EVAC canister. I was suspicious as I never double fill gas. Dealer didn't give me obd code. And they said valve replaced.

Ford Fusion in California, United States Dec 2010 - Apr 2013
Apr 2011 11000 mi	Transmission problems - clunking noise/feel when changing gears. Shop could not replicate nor did codes show anything wrong so nothing was done.
Nov 2012 61000 mi	bearings replaced - took to shop some months prior but mechanic didn't hear the noise so no action. This time they did.
Apr 2013 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.

Ford Fusion in Maryland, United States Sep 2010 - Mar 2016
Sep 2015 108000 mi US $350	Throttle body needed to be replaced. My specific build date was not covered by recall.

Ford Fusion in Ohio, United States May 2011 - Jun 2018
Nov 2011 41700 mi	Battery was found to be defective and replaced. It was not under warranty.
Dec 2015 90000 mi US $300	tie rod replacement
Sep 2017 111000 mi US $115	Display for hybrid was not showing braking energy being saved back to battery. Turned out to be a display problem only. Software fix worked for a little while, but now doesn't work again.
May 2018 117000 mi US $1100	Tie rod loose

Ford Fusion in Texas, United States Oct 2011 - Jun 2018
Sep 2013 51000 mi US $235	Check Engine light on. Solution was to reprogram the computer. Seems weird to me too.
Feb 2015 80000 mi US $260	Headlight went out on trip, went to dealer in AL. Other headlight dimmed due to age, replaced. Said fog lights out, they work now but wonder if that was mistaken (pull out knob, not obvious). O2 sensor, causing Check Engine light to go on and off. Replaced it.
Jun 2017 107000 mi	Stranded at airport after trip, due to 12V battery. It was within the 36 month full warranty and replaced at no charge.
Mar 2018 140000 mi	LED tail lights started growing dim on one side. Lincoln dealer (this is actually a Mercury Milan) said both sides were affected and replaced at no cost.
Jun 2018 145000 mi US $150	Check engine light came on, MPG observed down a little. Emissions system repair.

Ford Fusion in Florida, United States Mar 2009 - Dec 2016
Dec 2011 34000 mi	Rattle developed in dash from missing insulation between two overlapping ventillation ducts.
Jun 2013 47000 mi US $140	Interior door handle broke and would not lock without extra action.
Sep 2013 51000 mi	Sensor in throttle body failed. Repaired under extended warranty.
Dec 2013 54000 mi	Right-front wheel bearing was making a little noise on slow turns but was otherwise unnoticed.

Ford Fusion in Ohio, United States Sep 2010 - Jun 2011
Oct 2010 2000 mi	Car accelerated when foot off gas pedal. Able to stop, noticed two yellow wrenches, turned off car and appeared to reset. Garage could not replicate, had car for almost one week, put monitor in car for 2 weeks with no further probems, yet!

Ford Fusion in California, United States Oct 2010 - Jun 2018
Jul 2010 500 mi	Warranty repair because car had gone into "fail-safe" mode. Was an internal control valve related to the emissions controls.
Oct 2013 41300 mi US $110	12V battery failed completely, without any advance symptoms. Replaced with a Bosch battery of greater capacity.
Aug 2016 64000 mi	Car suddenly lost all power on the freeway. Wife was able to limp at very slow speed on battery power a few miles to the dealer. Problem turned out to be a throttle body that had failed. Dealer replaced it under warranty.
Jun 2017 73000 mi	One Saturday, my wife started the car and got a zillion lights: Check engine, ABS failure, Advanctrac failure, and others. No brakes at all, pedal went all the way to the floor. I went there (20 miles) to investigate, discovered low brake fluid, and added some. With this we were able to limp it home slowly to the dealer. Brakes were unreliable, but the pedal would pump up enough to stop the car. Monday morning the dealer called to say the ABS unit was bad, and possibly another module but they'd need to replace the ABS module to be able to tell. Diagnostics showed 8-10 trouble codes including fatal failure of the ABS module. Luckily, our warranty still had about 2 weeks left, so it was covered. The other suspected module (HCU??) tested OK once the ABS was replaced. Shop time was 2-1/2 days.

Ford Fusion in California, United States Jul 2017 - Jul 2018
Jun 2018 150000 mi US $1500	CV joint Engine mounts

Ford Fusion in California, United States Sep 2016 - Oct 2021
Sep 2018 107500 mi	Throttle body actuator control system (intermittent P2112 code)
Jul 2021 120000 mi US $400	Hybrid engine works fine but needed software reprogramming so it would kick in with low end torque and during times that internal combustion engine not needed. Software updated to achieve close to original specifications electric motor operational logic. A reportedly needed software reset after 9+ years of operation - if owners make themselves aware. Remedial software programming should arguably should not be at such cost as it is manufacturing issue. Original hybrid battery and motor were fine.

Ford Fusion in Maryland, United States Jul 2021 - Jun 2022
Apr 2022 214000 mi US $1400	Front Calipers

Ford Fusion in Virginia, United States Apr 2009 - Nov 2010
Nov 2009 9800 mi	Sync system sent text msg to my phone stating I had a serious brake issue (no dash warning illuminated). System had old code that went active, dealer had to call Ford for instructions, reflashed. Sync system health-reported brake malfunction (unspecified). ABS code. Dealer had to reflash computer, no malfunction (stored code went active-unknown reason)

Ford Fusion in California, United States Jul 2009 - Mar 2011
Feb 2010 6700 mi	Hybrid Regenerating Brakes software flash
Mar 2011 19000 mi	Moonroof water leak into cabin. Noticed water at several points in car (A pillar, headliner along top of door glass, maplight area) Seal determined to be defective. Replaced moonroof glass and seal.

Ford Fusion in Ontario, Canada Feb 2013 - Mar 2018
Mar 2018 79360 mi C $250	tie-rod end fixed

Ford Fusion in California, United States Mar 2010 - Jun 2018
Jun 2018 112000 mi US $1000	Noise from front end in sync with road speed. Wheel bearings replaced.

Ford Fusion in California, United States Aug 2009 - Jun 2012
May 2010 8000 mi	Speedometer stopped working. Needle stayed at 0 MPH regardless of the speed of the car.

Ford Fusion in Georgia, United States Feb 2012 - Jun 2019
Oct 2012 82000 mi US $250	Replaced 02 sensor
Nov 2013 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.
May 2014 102000 mi US $85	Had to replace throttle body due to failure of part's electronics to properly open and close throttle valve, resulting in a wrench light.
May 2018 127000 mi US $315	Wheel bearing in left rear replaced due to noise when going down the road.

Ford Fusion in Indiana, United States Jun 2013 - Mar 2018
Apr 2014 48300 mi US $300	Fixed broken speedometer
Nov 2014 56800 mi US $460	Bent wheel bearing replaced.
Aug 2017 84898 mi US $151	Replaced battery

Ford Fusion in California, United States Mar 2011 - Mar 2016
Mar 2013 64000 mi US $150	Brake warning light illuminated while commuting to work. pedal became mushy and there was perceived reduction in brake performance. Research indicates its a rare software glitch with the software controlling the hybrid regenerative brakes.
Mar 2014 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. check engine light would turn on during long highway trips (~200 mi driving at highway speeds). This never occurred during my normal 30 mile commute or short trips. Decided to pay $150 to have the computer reflashed with the latest software.
May 2014 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.

Ford Fusion in Tennessee, United States Jul 2010 - Sep 2011
Mar 2011 25000 mi	Factory recommended re-flash for re-generative brakes
Sep 2011 38000 mi US $110	Drivers interior (plastic!!) door release broke with normal use.

Ford Fusion in Illinois, United States Jan 2010 - Jun 2011
Mar 2010 1000 mi	Replace passenger seat bottom leather which was curling/wrinkling; replace floor mats that said "mariner" instead of fusion Replace the chrome letter "I" in Hybrid that fell off the driver's side door; replace front Chrome grill that had the Chrome finish bubbling off already

Ford Fusion in Tennessee, United States Apr 2010 - Dec 2014
May 2014 50000 mi	bad purge valve

Ford Fusion in Pennsylvania, United States Oct 2010 - Jun 2011
Nov 2010 9000 mi	leak in sunroof diagnosed and repaired.

Ford Fusion in Alberta, Canada May 2010 - Jan 2017
Dec 2010 4340 mi	No heat in cabin once engine reached operating temperature, ford fix for this problem, cooling system pressure tested, degas cap replaced, removal of air from cooling system fixed problem as degas cap was leaking.
Mar 2011 7440 mi	One integrated key fob quit working, key had failed, dealer replaced under warranty
Jun 2013 31620 mi	Engine light came on code for o2 sensor tab for reprogam fixed issue

Ford Fusion in New Brunswick, Canada May 2010 - Dec 2014
Jun 2010 8680 mi	Hybrid battery was loose in brackets causing a significant rattle. They removed the battery and re- seated it.
Sep 2012 20460 mi C $110	Inside driver side door handle broke (was not abused). The handle was replaced.

Ford Fusion in Ontario, Canada Oct 2015 - Jun 2018
Nov 2016 37400 mi C $700	Required replacement of hybrid system cooling pump

Ford Fusion in Minnesota, United States Jan 2010 - Jan 2019
Jun 2016 66000 mi US $387	Error P0130 02S11. Sensor faulty & replaced
Apr 2017 70000 mi US $300	During maintenance, it was determined that brake pads had to be replaced.

Ford Fusion in Florida, United States Oct 2009 - Sep 2018
Jan 2011 74700 mi	Speaker module for rear parking aid and cross traffic advisory intermittent. Speaker module replaced
Sep 2011 29000 mi	Instrument panel would occasionally have an uncommanded reset to the default mode. Software TSB performed.
Dec 2011 34000 mi	Front Passenger seat front up-down adjustment inop. Gear tooth broken.
Jun 2013 56000 mi US $150	Drivers inside door handle would not open door. Door handle replaced.
Sep 2013 58000 mi US $62	TPMS sensor had failed and was replaced during new tires installation
Jul 2015 74000 mi US $282	Drivers side interior door handle locking lever broke.
Apr 2017 89000 mi US $20	Driver side windshield washer nozzle cracked. Replaced with part ordered on internet.
May 2018 94000 mi US $25	Speaker module for back-up and cross traffic alert failed.

Ford Fusion in California, United States Nov 2015 - Jul 2018
Aug 2016 93000 mi US $200	Drivers side exit door handle broken inside of door panel.
Dec 2017 100200 mi US $100	Cross traffic alert warning system.
Mar 2018 103000 mi	Emissions purge valve

Ford Fusion in Texas, United States May 2013 - Feb 2016
Sep 2013 58000 mi US $650	O2 sensor malfunction
Mar 2014 64000 mi US $650	Cracked wheel bearing; made a grinding noise when making turns.

Ford Fusion in New York, United States Dec 2014 - Sep 2015
Dec 2014 80000 mi US $500	Ignition switch replaced
Jul 2015 91000 mi US $300	Battery failed

Ford Fusion in Connecticut, United States Jun 2011 - Mar 2014
Nov 2013 76100 mi	TPMS fault. All tires at correct pressure. Worse when cold or wet.
Feb 2014 81500 mi US $300	Replaced 2 TPMS sensors

Ford Fusion in California, United States Jan 2010 - Oct 2014
Dec 2011 29000 mi	Normal battery needed to be replaced after only 2.5 years.
Jan 2013 51800 mi US $190	Could not open the drivers door from the inside and the drivers door would not lock. The dealer fixed by replacing the inside door handle.
Jul 2013 48500 mi	Changed the tail light bulb. I did take more than 10 minutes to do it because the whole taillight needed to be disassembled.

Ford Fusion in Illinois, United States Jul 2010 - Jun 2018
Sep 2012 29000 mi	Dash on hybrid reset occasionally. The mpg would reset and dash displays would go to factory defaults.
Jul 2017 103000 mi US $350	One ignition coil pack was causing misfire. Replaced it along with all 4 spark plugs which were overdue.

Ford Fusion in Ohio, United States Aug 2016 - Sep 2016
Sep 2016 121000 mi	Gas pedal stopped working while driving. Was able to coast off the road safely. First dealer found nothing wrong. Second dealer said I needed a $3K transmission, but independent mechanics said that would probably not fix it.

Ford Fusion in Colorado, United States Nov 2013 - Sep 2017
Apr 2014 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.
Sep 2017 103000 mi	Transmission went out for 3rd time. Car sold to dealer.