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Expensive Ford Fusion repairs by problem area

Engine (29%)

Transmission and Drivetrain (20%)

Brakes and Traction Control (15%)

Suspension and Steering (23%)

Electrical and Air Conditioning (11%)

Paint, Rust, Leaks, Rattles, and Trim (2%)

Other (0%)

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Chart based on 105 repairs.

See TSBs and recalls for the Ford Fusion.

Ford Fusion repair cost distribution

$2500+ (21%)

$1000 - $2499 (79%)

$500 - $999 (0%)

$100 - $499 (0%)

< $100 (0%)

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Chart based on 67 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

71000 mi

US $1900

Car wouldn't start, brought in on May 5, battery replaced, picked up May 24 (we were on vacation in between), car wouldn't start AGAIN, car brought in again on May 25 and picked up June 10, APIM was bad and had to be replaced.

6780 mi C $140	Fuel module and gasket replaced under warranty and was subject to recall, but was also leaking fuel when filled, so vapor tube was also repaired. This seems to fix the leak but I have not driven the car since Dec 1 as I am in Hawaii.
24480 mi C $100	Windshield cracked with no sign of stone chip or bruise. Dealer would not do anything as they said they had a one year warranty on glass, as they had replaced windshield when I bought the car as it had stone bruise caused by dealership.
54994 mi C $1500	Fog light broken by rock, shop replaced light
73780 mi C $260	Power door locks stopped working. I pulled the fuse (hard to get at) but it was fine. Took to dealer and they had to reprogram radio module, charged 1 hour plus shop supplies and tax no parts required.

45000 mi US $175	Replaced rear brake pads and rotors.
79000 mi US $2000	Water pump failure. Also received new Water Pump, spark plugs, coolant, timing belt.

38000 mi US $200	Turn signal cancels were too sensitive. Dealer said the problem was not hardware, but required a small reprogramming of the software to fix.
76000 mi US $200	Battery failure. Not low and needed replacement, but full and immediate failure.
80000 mi US $100	Water Pump Failure
91349 mi US $250	Sway bar loose.
159719 mi US $350	Car was sputtering upon acceleration. Tune up was performed and spark plugs and wires were replaced.
165000 mi US $1300	Thermostat replaced Valve cover gaskets replaced - oil leak Timing Belt replaced

50000 mi US $152	Replace 12V battery
60000 mi US $170	Reprogram AC module and touchscreen display to make AC & heat functional again
75485 mi US $400	Had to replace engine mount, CV axle and repair transmission leak Troubleshoot and fix wiring. Reset engine light

29000 mi US $2155	Replaced electronic assist power steering module
58000 mi US $325	Front inside door handles won't retrack fully. Mechanism prevented locking of doors.
126000 mi US $150	Sound in front of car when stopping or take off from stop

66000 mi US $2800	All Wheel drive Power Transfer Unit leaking gear lube. Smell is noticable in winter with windows shut. Unit is only on AWD models of Edge, 500, and Fusion. Pricey little hunk of steel: 850+tax USD. Install is 8 hours, another $1200 bucks. But that's what a stimulus check is for I suppose. I was going around big bad Jeeps with that little Ford come the first big snow !
72000 mi US $250	Replace all 4 OEM rotors and pads and shims with Raybestos parts

74000 mi US $1900	Electric rack and pinion system died. Replaced power steering assembly.
74000 mi US $365	Control arms make constant noisy creaking sound. Dealership said nothing wrong with the car; that it was caused by the control arm bushing drying out. They said they could "fix" it for $1700 in control arms, or they could try lubing it.

133000 mi US $1000	passenger right rear caliper was frozen, caused premature wear of brake pads. RF lower control boot was split and also had excessive play. Both control arms were replaced
175000 mi US $800	calipers were sticking and pulling car to the right. Brakes, rotors, and calipers replaced.

47120 mi C $383	Noise form driver side, replaced one arm. Joint ball of passenger side suspension torn, replaced.
104160 mi C $5300	Car had no transmission in the middle of a trip. towed to dealer, Got checked and found transmission failed. Replaced with an used transmission. Never buy a ford again.

95000 mi US $1579	passenger front hub assembly required repair
95200 mi US $1150	ECM required replacement due to complete failure
99000 mi US $735	A/C compressor failed resulting in complete replacement of unit as well as flushing of complete system and evac/recharge
101000 mi US $118	Drivers interior door handle inoperable. Replaced interior door handle assembly
105000 mi US $194	left front headlamp assembly required replacement due to a faulty socket
106000 mi US $675	Noise and inability to do an alignment due to excessive wear.

90700 mi US $400	Battery cable was corroded and entire harness had to be replaced. Unable to just replace the positive battery cable.
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.
130000 mi US $1500	Flex plate cracked causing a loud knocking sound. The flex plate was replaced.

78000 mi US $200	Replaced faulty fuel filler neck
92100 mi US $1500	Cracked and leaking transmission cooler lines replaced Faulty ignition wiring harness causing two cylinders to misfire, including an injector completely failing due to bad wires. Bad accessory belt tensioner needed replacement.
105000 mi US $1500	Left and right control arm bushings worn. Replaced both control arms. Replaced front brake pads

30000 mi US $100	Drive side interior door handle broke. Replaced. (Seems to be a common problem).
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.
49000 mi US $450	Compass display always at North. New module ordered and installed.
56300 mi US $168	Driver's door handle failed (2nd time). These are very cheaply made and apparently fail often.
61000 mi US $1080	Leak in steering/AC condenser - unit replaced

90000 mi US $850	Vibration, worn transmission mount, replaced Tire sensor failed and replaced
98000 mi US $1600	Vibration worsening with time. 3rd trip to dealer to diagnose. Replaced all 3 motor mounts. Runs like new.
104000 mi US $350	Blower motor and temp sensor resistor replacement due to increasingly frequent loss of AC
105000 mi US $300	Intermittent A/C. Found to be a loose wire connector. Problem returned within 48hrs
105000 mi US $297	Loose connection in harness/connector causing interment blower operation, problem still agree acted by bumps.
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

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%.
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.
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."
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.
64000 mi US $947	Replaced both tie-rod ends, + front discs and pads.

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.
100000 mi US $2000	Brake bads replaced and caliper needed to be replaced, had to wait for them to get one.

37000 mi US $210	Engine check light. Dealer said error was for transmission and firmware update fixed it. Battery test failed. Battery was replaced
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
68000 mi US $1000	Driver's seat replacement due to a heating element failure

68820 mi C $280	Pulleys for drive belts were humming. Upper and lower tensioner pulleys replaced.
70560 mi C $160	Driver window would not go down. Cable for pulley system broke. Cable was replaced.
95960 mi C $275	Transmission lines were rusted and leaking in 2 location. New transmission lines installed.
98860 mi C $300	Front brakes rotors and seized calipers.
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.
104740 mi C $250	Tension pulleys making noise. Needed to be replaced.
105400 mi C $500	Both wheel bearings replaced Replaced front and back pads and rotors. Freed stuck calibers.
120500 mi C $300	Both sides have tie rods with excessive play in them.

109200 mi US $200	EVAP solenoid was bad
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
139000 mi US $1100	Front spring cracked. Replaced both springs and struts Exhaust flex pipe rusted out.
154000 mi US $750	Fuel smell in cabin while idling. Dealer found a spark plug loose. Also replaced valve cover, and a solenoid.
188000 mi US $500	Transmission cooler lines were leaking

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.
120300 mi US $100	Upper motor mount replaced.
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.
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.
130000 mi US $200	Tire pressure sensors replaced. Ordered VDO sensors from Rock Auto and had my mech install.

45880 mi C $160	Serpentine belt was worn and needed replacing. Replaced by backyard mechanic using an AC Delco belt
57660 mi C $200	Cracked spring on left front. Replaced whole strut/spring assembly for ease of repair and cost.
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.
68200 mi C $1250	Electric steering rack failed, needed replacement.

90000 mi US $300	tie rod replacement
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.
117000 mi US $1100	Tie rod loose

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.
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.
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.

55860 mi C $100	Weak battery under stress. Replaced to avoid problem in the winter.
83700 mi C $500	Replace 2 front wheel bearings
143220 mi C $1500	Replace intake gasket to stop oil leak. replace one catalytic convertor and front end of exhaust

Expensive Ford Fusion repairs by problem area

Ford Fusion repair cost distribution

2017 Ford Fusion 4dr Sedan

2015 Ford Fusion 4dr Sedan

2014 Ford Fusion 4dr Sedan

2013 Ford Fusion 4dr Sedan

2013 Ford Fusion 4dr Sedan

2013 Ford Fusion 4dr Sedan

2013 Ford Fusion 4dr Sedan

2013 Ford Fusion 4dr Sedan

2012 Ford Fusion 4dr Sedan

2012 Ford Fusion 4dr Sedan

2012 Ford Fusion 4dr Sedan

2011 Ford Fusion 4dr Sedan

2011 Ford Fusion 4dr Sedan

2011 Ford Fusion 4dr Sedan

2011 Ford Fusion 4dr Sedan

2011 Ford Fusion 4dr Sedan

2010 Ford Fusion

2010 Ford Fusion 4dr Sedan

2010 Ford Fusion 4dr Sedan

2010 Ford Fusion 4dr Sedan

2009 Ford Fusion 4dr Sedan

2009 Ford Fusion 4dr Sedan

2008 Ford Fusion 4dr Sedan

2008 Ford Fusion 4dr Sedan

2008 Ford Fusion 4dr Sedan

2008 Ford Fusion 4dr Sedan

2007 Ford Fusion 4dr Sedan

2007 Ford Fusion 4dr Sedan

2007 Ford Fusion 4dr Sedan

2006 Ford Fusion 4dr Sedan

2006 Ford Fusion 4dr Sedan

2006 Ford Fusion 4dr Sedan

Ford Fusion Expensive Problems

55000 mi US $150	Interior door latch for driver's door broke. Door could not be opened from the inside.
59600 mi US $2100	Moon roof track was broken and motor contained plastic shards from the track.

48360 mi C $1290	Repair oil leak from oil pan and engine output seal
84320 mi C $200	Replaced coolant manifold and temperature sensor due to leak at coolant temperature sensor.

85000 mi US $2100	PCM failed and damaged the ignition coils and plugs requiring replacemet of all items.
105000 mi US $150	Wheel bearings went bad on the front end. Both were replaced.

45260 mi C $218	Car began showing symptoms of hard/long cranking (also SRS light would not go out after car started)
85560 mi C $1700	Noise and vibration when driving from right side of car. Dealership diagnosed as two bad right side wheel bearings (front/rear) both replaced and car returned to normal operation

54000 mi US $604	All new brake pads & rotors, balky (sticking) LR caliper freed up. Even 3,000 miles later, car stops like brand new. Gas mileage went up 2 mpg city with LR caliper fixed. Corroded spot fixed on a wheel lip causing a tire leak at the bead.
46300 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. Noticed an oil burning smell inside the car when not in motion, the engine warmed up & running. No visible smoke. Dealer replaced valve cover gasket & cleaned the engine.
80000 mi US $697	Engine light came on, I checked it & it read PO128 : a bad cooling thermostat. Car had been running cool so it was obviously stuck open. Garage changed it for $199.56 Front end squeak while turning at low speeds. Garage said tie-rod ends were bad & could be the problem, but said it''s usually ball joints even though mine were in good shape. Tie-rod ends replaced at $148.04 note ...The front end squeak never went away and I suspected my ball joints were very dry inside. In March I bought and used a grease needle. A ten-minute job and the car's front end is very quiet now :)
82083 mi US $694	Replaced all brake rotors and pads plus two calipers Recharged A/C system
88000 mi US $120	Power door lock actuator for the front passenger door failed. Bought a new one for $120 and replaced it myself.
88500 mi US $264	Had a fluid drip - not engine coolant - under the radiator. A local repair shop found the transmission lines going to the cooler built into the radiator were leaking and replaced them.

64700 mi US $125	Airbag light came on and stayed on. Electrical system acting "funny". Turns out the battery failed to hold a charge and once it was replaced the airbag light stayed off and things seem normmal again.
113000 mi US $200	replace (1) oxygen sensor replace sensor in dashboard that was preventing the AC compressor from running replace leaking transmission cooler lines that run to the radiator, Slow leak. Showed a red spot under that car when parked overnight.
118000 mi US $1000	Replace both tie rod ends. Steering wonky. replace sway bar links - front. Making noise Replace both rear calipers. Brakes were repaired recently but calipers were problematic and should have been done earlier.
122000 mi US $120	airbag light comes on and stays on when starting engine. engine cranking slow. Needed a jump once because battery died on a short trip. Replaced battery and all is well again. No airbag light with new battery.

98600 mi US $1200	The module in the instrument cluster broken in order to get the panic button to the key fob to work had to replace cluster.
110000 mi US $175	Door lock front right door was not locking replace interior mechanism and handle and lock.
115000 mi US $140	Brake Switch Transmission would not shift
122000 mi US $145	Low oil pressure light came on Oil leak was fixed.
128000 mi US $625	Right Rear Sway Bar and Right Front Tie Rod also had some door dent bumped out and rear seat work done patch job

64480 mi C $1400	This car has been a disaster since the day i got. shaft in transfer case replaced, both front half axle shafts, balljoint, hanger bearings x 2, and 1 front wheel bearing. This is a car I have only owned since dec of 2008 not impressed ford
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

18600 mi C $200	car 2x would not start
19220 mi C $480	electrical problem, would not start sulfur smelle
42160 mi C $500	Unintended acceleration. The dealer could find no problems. Electrical -running lights wouldn't turn off, locks wouldn't work.
47120 mi C $1600	Replace wheel bearings front and rear.

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.
118500 mi US $230	Squeaking and uneven tire wear caused by worn out struts. Replaced front struts and rear shocks.
140000 mi US $1100	Failed transfer case was causing loud grinding noise. Needed replacement.
166000 mi US $200	Right front wheel bearing