Every vehicle has a unique set of strong points and shortcomings. The Ford Fusion is no different. This model line is a popular choice among many car owners for its excellent performance, efficiency and comfort, but there are a few common problems with the Ford Fusion that current and prospective owners should know about.

Developing an understanding of the typical Ford Fusion issues and weighing them against its advantages can help you make important ownership decisions about these vehicles.

Is the Ford Fusion Reliable?

While it's no longer in production, the Ford Fusion is a pretty reliable car, and you'll still see many of them out on the road. Whether you're wondering whether you should purchase one or need to decide if repairing yours is worth the money, you can start by learning more about the Ford Fusion's reliability and performance.

Innovative Features

With its initial release in 2006, the idea behind the Fusion was to provide an affordable sedan that offered superior passenger comfort. This model features ample interior space, giving occupants more room to spread out and relax in style on long drives.

Over the years, Ford added to their initial design by including newer technology and updated safety features. Radars, sensors and cameras are used to assist in parking, utilize cruise control and sense nearby traffic. Other inclusions, such as an infotainment system, increased the vehicle's luxurious nature and usability, allowing for hands-free calls, GPS and more.

Fuel Efficiency

Ford Fusion models are designed with fuel efficiency in mind, offering gasoline and hybrid options for customers. Most Ford models utilize an EcoBoost engine, which injects fuel directly into the engine to optimize performance.

The Fusion typically offers 388 miles on a full tank, getting an estimated 21 miles per gallon in the city and 31 on the highway, with a combined mpg of 25. Ford Fusion Hybrid models utilize less gasoline, using electric power in tandem to ensure you're getting the most value for your money at the pump.

Life Span

The Ford Fusion line was at the top of the midsize sedan industry for 14 years. Despite some of the problems mentioned above, the Ford Fusion has a reputation for reliability, regularly reaching upwards of 200,000 miles for its owners. Throughout its life span, it has maintained high ratings on popular sites like Kelley Blue Book, often maintaining expert and consumer ratings above 4.0 out of 5.0.

As Ford has worked out kinks with their older models, newer models have reaped the rewards with improved handling, performance and comfort.

6 Common Issues in the Ford Fusion

Every car has its problems that may require replacements or repairs to keep it running at its best. Before conducting needed maintenance, you should be aware of potential defects and issues with your specific model. Below are common problems owners have encountered when owning a Ford Fusion.


In 2021, Ford recalled almost 2.6 million vehicles in the United States due to problems with their airbags. Many of these vehicles were Ford Fusions manufactured between 2006 and 2012. These models were found to have issues with their driver's side front Takata airbag, which had the potential to rupture and possibly release sharp metal fragments into the cabin. These unpredictable explosions could result in severe injury or even death.

If you are on the market for a Ford Fusion or have one sitting in your garage, make sure to run the vehicle identification number on Ford's website to find out if yours has been recalled.


Another known Ford Fusion issue concerns the braking system. Some common problems with the brakes on 2006 to 2010 Fusion models include:

  • The car requiring extended time to stop after pressing the brake.
  • Brake failure and the pedal falling to the floor while driving.
  • Extra pressure being needed to stop the car.

After investigation, these problems in the Ford Fusion were linked to valves not closing correctly within the ABS hydraulic control unit. Similarly, Ford also recalled particular 2014 and 2015 models due to an issue where environmental exposure caused the brake pedal bumper to disintegrate and detach from the brake pedal. These problems increase the likelihood of crashes and injuries.

Head Gasket

The head gasket plays a vital role in sealing the gap between the cylinder head and engine block, building appropriate pressure to maintain engine power. It also keeps the oil and coolant separate, which protects your engine from overheating and catching fire.

In Ford Fusion designs from 2013 to 2019 equipped with the 1.5L and 2.0L EcoBoost engines, customers have noticed frequently blown head gaskets, causing oil and coolant to leak into the engine. As a result, many owners have had to deal with expensive repairs and replacements for failed engines.

Power Steering

One of the most common problems associated with the Ford Fusion concerns its power steering system. Power steering is responsible for reducing the effort required to turn the steering wheel, so when this system fails, vehicles feel immensely “heavy” and are extremely difficult to turn.

These issues were found to be caused by one of two problems. The first occurred in select 2011 and 2012 models without a 3.5L engine, with steering motor sensor faults causing power steering failure. These vehicles were subsequently recalled to have their steering gear replaced and power steering control module software updated.

The second instance of power steering failure occurred in Ford Fusion vehicles manufactured between 2013 and 2016. This instance was connected to regions with heavily salted roads in the winter. With exposure to the salt and other contaminants, the power steering gear motor attachment bolts become corroded and cause the steering gear motor to detach.


As a Ford Fusion ages, it may experience transmission leaks — this is true for both automatic and manual transmission models. Oil leaking from the left side half-shaft area of the transmission becomes increasingly prevalent as the vehicle's axle shaft wears down.

Transmissions also have a difficult time shifting as mileage increases. Many automatic Fusion models experience harsh, delayed or slipped shifting that results in excessive jerking or jolting. Others lose the ability to change into a higher gear, preventing drivers from accelerating at times.

These issues grow out of an assortment of problems, from outdated powertrain control and transmission control module software to needing valve body replacements or a total transmission rebuild. Depending on the problem with your Ford Fusion, you could be looking at costly repairs or replacements.

Lug Nuts

While changing a flat tire is a hassle, it's usually not too complicated to complete — unless your lug nuts swell. Many Ford Fusion owners experience swollen lug nuts stemming from an issue in Ford's design process. These nuts have a steel core covered with a chrome, aluminum or stainless steel cap. When it gets hot, this cap is known to expand and separate, making it increasingly difficult for users to remove the nuts with the standard wrench supplied by Ford.

Shop for the Ford Fusion Parts You Need at StockWise Auto

Whether you own a Ford Fusion or are thinking about purchasing one, it's essential to have the parts and equipment you need to conduct regular maintenance and keep it in top condition. StockWise Auto maintains a vast inventory packed with the latest Ford Fusion parts to help you find what you need.

Take a look at our catalog and purchase the parts you need for your repair or replacement project. If you have any questions or concerns, please feel free to contact our team online.