| 1 | 0 | 3 | 4 | 3 | 4 |
Ford Fusion repairs by problem area
Engine (25%)
Transmission and Drivetrain (11%)
Brakes and Traction Control (6%)
Suspension and Steering (9%)
Electrical and Air Conditioning (28%)
Paint, Rust, Leaks, Rattles, and Trim (13%)
Other (7%)
Select a problem area
- Engine
- Transmission and Drivetrain
- Brakes and Traction Control
- Suspension and Steering
- Electrical and Air Conditioning
- Paint, Rust, Leaks, Rattles, and Trim
- Other
Chart based on 2173 repairs.
Ford Fusion brake repair cost distribution
$2500+ (0%)
$1000 - $2499 (13%)
$500 - $999 (19%)
$100 - $499 (37%)
< $100 (31%)
Chart based on 120 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
2018 Ford Fusion 4dr Sedan
turbocharged 325hp 2.7L V6 6-speed shiftable automatic AWD
| 6000 mi | Noise and vibration coming from front rotors. Dealer pulled wheels and inspected and cleaned rotors and brakes pads. |
2017 Ford Fusion 4dr Sedan
turbocharged 325hp 2.7L V6 6-speed shiftable automatic AWD
| 20460 mi C $250 |
Rear brake rotor and disk rust out completely, replaced under warranty. |
| 42000 mi | Front rotors warped. Dealer turned them on a lathe Rear rotors warped causing vibration at higher speeds. Dealer said couldn’t help since out of warranty. Many others are experiencing the same issues with the Fusion Sport on our Facebook group. |
2017 Ford Fusion 4dr Sedan
turbocharged 181hp 1.5L I4 6-speed shiftable automatic FWD
| 19000 mi | Warped rotors on all 4 wheels. |
2017 Ford Fusion 4dr Sedan
141-horsepower 2.0L I4 Plug-in Hybrid CVT FWD
| 62000 mi US $985 |
Salt from driving in Wisconsin had reduced contact area on the rotors to about 50%. Pins that calipers moved on were corroded and sticking, limiting braking effectiveness. Original brake pads were down to 20% remaining. |
2016 Ford Fusion 4dr Sedan
turbocharged 240hp 2.0L I4 6-speed shiftable automatic AWD
| 66960 mi C $41 |
maintenance rear brakes was 3m, replaced rotors below spec. has nav. system repaired also. |
2015 Ford Fusion 4dr Sedan
turbocharged 240hp 2.0L I4 6-speed shiftable automatic FWD
| 46000 mi US $321 |
TIRES. |
| 93000 mi US $750 |
replace brake pads and rotors all around |
| 29000 mi US $300 |
Rear pads replaced due to the calipers "hanging up" due to the caliper slides needed lubed. Along with rear pad replacement, all four calipers were lubed. |
2015 Ford Fusion 4dr Sedan
175-horsepower 2.5L I4 6-speed shiftable automatic FWD
| 150015 mi US $1200 |
lost rear break function. Break caliper replaced electric parking break replaced break fluid replaced. |
| 157000 mi | front brake hoses replacement |
2015 Ford Fusion 4dr Sedan
141-horsepower 2.0L I4 Hybrid CVT FWD
| 61000 mi US $500 |
No Know problem but noticed wear/rust on brakes |
2013 Ford Fusion 4dr Sedan
turbocharged 240hp 2.0L I4 6-speed shiftable automatic FWD
| 14000 mi US $157 |
Dashboard lit up like Christ mas tree. ABS light, Check rear park aid, Air Bag, Hilltop Assist "Off" warning. My OBDII scanner was unable to connect so I took vehicle to the dealer. A faulty ABS sensor was found to be the cause off the issue. Since it was no longer "online" it took out all the other computers in the daisy chain. The repair cost was very reasonable, this Dealership is family owned and provided incredible customer service. |
| 13800 mi US $200 |
Rear calipers had frozen on the slides from low usage. Rear pads were worn down to 4mm, Replaced front and rear rotors and pads. Cleaned and lubed all caliper slides. |
| 16000 mi | Clicking again this time resolved by chauffeuring the pads and re greasing slider pins. |
| 27000 mi | Calipers sticking and replaced |
2013 Ford Fusion 4dr Sedan
turbocharged 240hp 2.0L I4 6-speed shiftable automatic AWD
| 39400 mi US $496 |
Animals chewed under-hood wires |
| 160000 mi US $200 |
replaced damaged/blown brake line front passenger side. synthetic oil change |
2013 Ford Fusion 4dr Sedan
turbocharged 178hp 1.6L I4 6-speed shiftable automatic FWD
| 45000 mi US $175 |
Replaced rear brake pads and rotors. |
2013 Ford Fusion 4dr Sedan
175-horsepower 2.5L I4 6-speed shiftable automatic FWD
| 72000 mi US $250 |
Rear pads and rotors |
2013 Ford Fusion 4dr Sedan
141-horsepower 2.0L I4 Plug-in Hybrid CVT FWD
| 15000 mi | Car self-diagnostic indicated brake system issue, very likely related to an unknown issue before I took ownership that had already been resolved. |
2013 Ford Fusion 4dr Sedan
141-horsepower 2.0L I4 Hybrid CVT FWD
| 100000 mi US $1400 |
Rear rotors worn beyond spec, rear pas worn out, left side tires worn to belts on inside |
| 36000 mi | Brake ABS system...subframe chaffed harness |
| 36000 mi | Parking brake light comes on randomly while driving. |
| 39000 mi | Parking brake light comes on randomly while driving. Shop could not duplicate |
2012 Ford Fusion 4dr Sedan
240-horsepower 3.0L V6 6-speed shiftable automatic FWD
| 37000 mi US $90 |
All brake pads worn. |
| 23560 mi C $350 |
rotors needed to be turned |
| 31600 mi C $600 |
Severe brake fade. Total brake loss. Dealer could not duplicate. I took the car home and found my rear calipers siezed and the pads failed. I replaced all pads/rotors/calipers myself and the problem was resolved. |
2012 Ford Fusion 4dr Sedan
175-horsepower 2.5L I4 6-speed automatic FWD
| 127720 mi C $1500 |
Replace brake pads and rotors |
| 74000 mi US $303 |
I had brakes checked and was told I needed pads on front and rear..I took to my mechanic who said I only needed front pads.After removing found that the calipers were frozen on both side..So I had to replace both calipers. First time since I had the car. |
2011 Ford Fusion 4dr Sedan
263-horsepower 3.5L V6 6-speed shiftable automatic FWD
| 1000 mi | They replaced one wheel sensor and ABS module. |
2011 Ford Fusion 4dr Sedan
263-horsepower 3.5L V6 6-speed shiftable automatic AWD
| 72000 mi US $250 |
Replace all 4 OEM rotors and pads and shims with Raybestos parts |
2011 Ford Fusion 4dr Sedan
240-horsepower 3.0L V6 6-speed shiftable automatic FWD
| 133000 mi US $1000 |
passenger right rear caliper was frozen, caused premature wear of brake pads. |
| 175000 mi US $800 |
calipers were sticking and pulling car to the right. Brakes, rotors, and calipers replaced. |
2011 Ford Fusion 4dr Sedan
175-horsepower 2.5L I4 6-speed manual FWD
| 57000 mi US $75 |
Rear brake caliper was sticking. |
2011 Ford Fusion 4dr Sedan
175-horsepower 2.5L I4 6-speed automatic FWD
| 105000 mi US $1500 |
Replaced front brake pads |
| 204000 mi US $430 |
ABS sensor stuck, brakes soft and went almost to the floor; pads rotors also replaced for first time since buying the car in 2012 |
| 25000 mi | Electronic stability control (Advancetrac) warning light and warning message was intermittently coming on and turning off at low and high speeds, dealer was unable to replicate problem. Problem has not occurred in the month afterwards. |
| 56000 mi US $200 |
Front and rear brakes |
| 47000 mi US $140 |
Replaced rear rotors and pads |
| 2000 mi | Car computer display reported AdvanceTrac needed service. Dealer diagnosed control module needed to be replaced but did not have it in stock. Dealer ordered it for next day repair. AdvanceTrac module was successfully replaced. New car so covered under warranty. |
2011 Ford Fusion 4dr Sedan
156-horsepower 2.5L I4 Hybrid CVT FWD
| 99200 mi C $700 |
rear brake pad replacement and front brake cleaning |
2010 Ford Fusion 4dr Sedan
263-horsepower 3.5L V6 6-speed shiftable automatic FWD
| 27800 mi | 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 |
| 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) |
| 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. |
2010 Ford Fusion 4dr Sedan
240-horsepower 3.0L V6 6-speed shiftable automatic FWD
| 15300 mi | Replaced leaking master cylinder cap. |
2010 Ford Fusion 4dr Sedan
240-horsepower 3.0L V6 6-speed shiftable automatic AWD
| 128000 mi US $800 |
Replace brake caliper and rotor, consequently master cylinder brake. |
| 68000 mi US $300 |
Parking brake froze during the winter and prematurely wore out the brakes. |
| 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. |
2010 Ford Fusion 4dr Sedan
175-horsepower 2.5L I4 6-speed manual FWD
| 128960 mi C $700 |
Parking brake caliper, pad and cable replaced. |
| 32000 mi US $180 |
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. |
2010 Ford Fusion 4dr Sedan
175-horsepower 2.5L I4 6-speed automatic FWD
| 122000 mi US $1200 |
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. |
| 68000 mi | Pads, rotors, calipers |
| 84000 mi US $130 |
warning light on brake air pressure |
| 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. |
| 89000 mi US $320 |
left rear pads wore out in one year, replaced defective caliper and installed new rotors |
| 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. |
| 98860 mi C $300 |
Front brakes rotors and seized calipers. |
| 105400 mi C $500 |
Replaced front and back pads and rotors. Freed stuck calibers. |
| 19780 mi | back passenger caliper became stuck and needed replacement along with pads and rotor. |
| 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. |
| 100000 mi US $2000 |
Brake bads replaced and caliper needed to be replaced, had to wait for them to get one. |
| 145000 mi US $150 |
Replaced rear rotors ,calipers and brakes |
| 130000 mi | Front and rear rotors and pads. Rear pads were shot. |
| 154360 mi C $637 |
front and rear brake pads rotars calipers |
| 130200 mi C $100 |
stuck emergency brake |
2010 Ford Fusion 4dr Sedan
156-horsepower 2.5L I4 Hybrid CVT FWD
| 25000 mi | Factory recommended re-flash for re-generative brakes |
| 9800 mi | Sync system health-reported brake malfunction (unspecified). ABS code. Dealer had to reflash computer, no malfunction (stored code went active-unknown reason) |
| 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. |
| 70000 mi US $300 |
During maintenance, it was determined that brake pads had to be replaced. |
| 6700 mi | Hybrid Regenerating Brakes software flash |
| 214000 mi US $1400 |
Front Calipers |
2009 Ford Fusion 4dr Sedan
221-horsepower 3.0L V6 6-speed automatic FWD
| 90000 mi US $30 |
Brake interlock switch broke preventing shifting out of park. I replaced the switch |
| 97000 mi US $936 |
Brake fluid was leaking from the master cylinder and there was a leak in the power steering pressurize line. Replaced the master cylinder & power steering line. |
| 28000 mi US $270 |
Brake caliper froze and needed to be sandblasted, greased, and new pads installed. $270 for a rear brake job on car with under 28,000 miles. |
| 91500 mi US $300 |
Second time our brake calipers have had issues due to corrosion. Bead blasting and all new brake seals are a pain to deal with once, let alone twice. |
2009 Ford Fusion 4dr Sedan
160-horsepower 2.3L I4 5-speed manual FWD
| 17000 mi | front brakes made a click or pop noise once when cold when backing out of the garage, Clips were installed to eliminate the noise. |
2009 Ford Fusion 4dr Sedan
160-horsepower 2.3L I4 5-speed automatic FWD
| 59700 mi US $500 |
Caliper froze. Caused pads and rotor damage, had to replace all. |
| 11000 mi | Car makes metallic clunk noise occasionally when switching from D to R or R to D and then applying brakes. Issue was fixed at dealer but then came back. Still not fixed. |
| 194060 mi C $375 |
Replaced pads and rotors. Parts supplied. |
2008 Ford Fusion
Engine not specified
| 102000 mi | Brakes gradually stopped working, Fluid was leaking, And needed to be replaced |
2008 Ford Fusion 4dr Sedan
221-horsepower 3.0L V6 6-speed automatic FWD
| 89680 mi C $500 |
front right caliper and rear left caliper were changed in Canadian Tire store for 500$. The problem was premature end of life of pads because the caliper was frozen. The warranty on pads and disk was used |
| 184000 mi US $725 |
Hydraulic Control Unit was replaced to correct low brake pedal due to stuck valves in HCU. This is a common Fusion problem. HCU cost was $600, labor was $125. |
| 190000 mi US $100 |
Replaced master cylinder to resolve soft brake feel and too much pedal travel. |
| 13000 mi | Brake caliper :snapping on the disk when brake is applied . |
| 115550 mi | ABS module replaced |
| 117461 mi US $500 |
Brakes, rotors replaced Rear brake calipers replaced |
2008 Ford Fusion 4dr Sedan
221-horsepower 3.0L V6 6-speed automatic AWD
| 167000 mi US $300 |
One rear brake was sticking. The caliper and pads were replaced. I had previously replaced the caliper myself, but the one I installed apparently was defective. The driver's side caliper apparently had been sticking somewhat for several years, as that wheel was often hotter than the others and the pads wore out more often. |
2008 Ford Fusion 4dr Sedan
160-horsepower 2.3L I4 5-speed manual FWD
| 189000 mi US $400 |
Brakes |
| 81000 mi US $10 |
Daughter reported soft brake pedal. After application of ABS (hard braking) pedal would be very soft and brake performance was poor. Did complete brake fluid flush by manual bleeding which solved problem. Amazing improvement. |
2008 Ford Fusion 4dr Sedan
160-horsepower 2.3L I4 5-speed automatic FWD
| 135500 mi US $800 |
Braking ability diminished, ABS hydraulic and control module replaced. |
| 87000 mi US $900 |
Rear brake replacement |
| 94240 mi C $400 |
Back brakes |
| 52200 mi US $175 |
Rattle from both rear calipers. Both rear calipers were loose. Replaced mounting hardware and remounted calipers. |
| 58000 mi US $800 |
Replaced front rotors for 2nd time, front brake pads and 4 new tires. |
| 60000 mi US $150 |
Had to replace rear caliper hardware again. |
| 54000 mi US $604 |
All new brake pads & rotors, balky (sticking) LR caliper freed up. Even 3,000 miles later, car stops like brand new. Gas mileage went up 2 mpg city with LR caliper fixed. |
| 68800 mi US $1989 |
In mid-Nov.'14 my brake pedal nearly went to the floor as the ABS kicked in. It didn't recover until the next day, then it was fine for 6 weeks. On 1-3-15 it happened again & stayed that way. Dealer replaced master cylinder & HCU. |
| 70000 mi US $461 |
Left-rear brake caliper had seized, causing those pads to drag & make the whole assembly hot. A garage had freed it up in Spring 2014 but it obviously only lasted a year-and-a-half. A local Ford dealer replaced the caliper this time. |
| 82083 mi US $694 |
Replaced all brake rotors and pads plus two calipers |
| 107000 mi US $330 |
Parking brake sticking on rear passenger wheel. Cleaned hardware and replaced rotors and pads. Problem solved. |
2007 Ford Fusion 4dr Sedan
221-horsepower 3.0L V6 6-speed automatic FWD
| 99800 mi US $75 |
Replaced caliper carriers, front, both. Caliper pins frozen and no longer allowed calipers to move back and forth. |
| 118000 mi US $1000 |
Replace both rear calipers. Brakes were repaired recently but calipers were problematic and should have been done earlier. |
| 282000 mi US $381 |
Driver's side rear brake caliper replaced. Brake pads replaced same visit. Driver's side rear brake caliper replaced. Brake pads replaced same visit. |
| 119000 mi US $800 |
Full brake rebuild - new pads, rotors and replaced all four calipers with rebuilt units because the OE calipers were "sticky" from accumulated corrosion. |
2007 Ford Fusion 4dr Sedan
221-horsepower 3.0L V6 6-speed automatic AWD
| 148800 mi C $500 |
Brakes all around |
| 67900 mi US $250 |
Left rear caliper sticking. Replaced along with wear items (pads and rotors). |
2007 Ford Fusion 4dr Sedan
160-horsepower 2.3L I4 5-speed manual FWD
| 61380 mi C $365 |
Driver side rear caliper was sticking |
| 111000 mi US $350 |
Frozen parking brake cable. Needed replacement. |
| 133000 mi US $100 |
brake rotors, pads, park brake adjustment. |
2007 Ford Fusion 4dr Sedan
160-horsepower 2.3L I4 5-speed automatic FWD
| 136000 mi US $1000 |
Warped rotors. Brake rotors replaced. |
| 92000 mi US $150 |
replace [brakes] |
| 102800 mi US $10 |
Replaced Slide Pin Bushings on Rear Caliper slide pins due to swelling causing excessive brake drag. |
| 89000 mi | One of the brake pads was rattling on the rotor. Removed the brake pad and sanded it down so it was even then reinstalled. |
| 96000 mi US $250 |
Replaced the rear brake calipers, rotors, and brake pads. |
2006 Ford Fusion 4dr Sedan
221-horsepower 3.0L V6 6-speed automatic FWD
| 16120 mi C $45 |
"low brake fluid" warning message. Dealer said no code present. Took it in when light finally went on near dealer store. Dealer said master cylinder sensor bad. (ya think?) On repair invoice described part as brake switch. Paid labour only. |
2006 Ford Fusion 4dr Sedan
160-horsepower 2.3L I4 5-speed manual FWD
| 95480 mi C $1000 |
Pads, rotors, calipers, front and rear |
| 167000 mi US $680 |
Brake reservoir. Didn't fix problem now dealer wants 1100.00 to replace abs valve. |
| 139000 mi US $550 |
Driver suspected Clutch issue. Turned out the R.R. Brake Pad fell apart and lodged causing drive and smell issues. Had car inspected for safety and repairs made. |
2006 Ford Fusion 4dr Sedan
160-horsepower 2.3L I4 5-speed automatic FWD
| 215400 mi US $1000 |
replace 4 brake rotors, calipers, pads, hoses |
| 97000 mi US $400 |
Valve assembly. |
| 104160 mi C $200 |
The back passenger brake caliper was sticking. I live in a Canadian climate where roads get salted every winter. The caliper piston was corroded and pitted. A friction ready replacement was much faster than attempting a piston replacement and not that much more expensive. I did both sides to avoid having to do the other next winter. |
| 53940 mi C $200 |
Brake pedal went down all the way and brakes were very weak. The service shop said that they bleeded the ABS system and if it happens again will have to replace it. |
| 55580 mi C $100 |
Brake pedal went down all the way and brakes were very weak. Replaced master cylinder and ABS module covered under extended warranty. |
| 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. |
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