2006-2009 Ford Fusion: problems, engines, what to look for

The Ford Fusion offers a solid powertrain, excellent highway handling and comfortable ride. It shares its platform with the 2003-2008 Mazda 6, as well as the Mercury Milan and the Lincoln Zephyr. The 4-cylinder Fusion comes with a 5-speed manual or 5-speed automatic transmission. The V6 Fusion has a 6-speed automatic and is also offered with all-wheel drive. The Ford Fusion is not very expensive and can last long if you take good care of it. What are the reported problems?

Reported problems: The overall number of complaints for the 2006-2009 Ford Fusion is fairly small. Even the next-generation 2010 Fusion has drawn more complaints on the NHTSA website than all 2006-2009 model years combined. There is a fair amount of complaints about automatic transmission problems in the 2006, 2007 Fusion. The good news is that a used transmission for this vehicle is not very expensive. The labor cost to replace the transmission varies from 6 to 10 hours. A bad or sticking thermostat in the 2.3L engine can cause the Check Engine light to come on in colder weather with the trouble code P0128. Replacing the thermostat (it comes with the housing as one unit) will cost 1.5 hours of labor plus the part ($30-$60) and coolant to top up. It's not a very difficult repair. Here are a few videos showing the thermostat replacement. After the repair, the air must be bled properly from the cooling system. One of the symptoms of air trapped inside the cooling system is a lack of heat from the air vents when the engine runs at idle.

It's also fairly common for other plastic outlets and flanges of the cooling system to leak, as they become brittle with age. The problem with coolant leaks is that if not repaired in time, they can lead to loss of coolant and overheating. As you know, overheating can significantly shorten the engine's life or in worst cases, damage it beyond repair. For this reason, it's a good idea to check the coolant level regularly and repair coolant leaks as soon as possible.

In a 3.0L Duratec V6, oil leaks are common. One particular source of the leak is the place where the valve cover meets the timing chain cover. Changing both valve cover gaskets takes some time (over 4 hours of labor). Your mechanic may also need to use some sealant in leak-prone areas. According to this video, when doing this job, it's a good idea to check the camshaft cap bolts, because if any of them come loose, it can lead to a very expensive repair. If you are buying a used Ford Fusion with a 3.0L V6 engine, watch out for engine noises and leaks. Another problem with oil leaks is that the oil can get on the drive belt and cause it to break.

The Ford Fusion has two (short and long) lower control arms and one upper control arm on each side in the front suspension. This setup allows for excellent handling and smooth ride, but may require more front end work at higher mileage. Lack of grease inside the ball joints of the control arms can also cause a creaking noise when driving over bumps. When replacing control arms, we recommend using OEM parts, as we have had a bad experience with aftermarket control arms for this vehicle. OEM parts are listed at $112-$130 for the short lower arm and $200-$220 for one long lower arm Read also: When do the control arms need to be replaced?

The brake calipers are fairly common to seize up at higher mileage and may need to be replaced. Read more about brake calipers.

Engines: The 160-hp 2.3L DOHC is a very good reliable Mazda-sourced motor. It has a timing chain that doesn't need any maintenance. We have seen this motor last over 250,000 miles and, if needed, it's not very expensive to replace with a used unit.
The 3.0-liter 24-valve Duratec V6 offers 221 horsepower and also has a maintenance-free timing chain. It's one of the best Ford V6 engines and is proven to be really durable with good care. It even has one big plus over the next generation Duratec V6: The water pump is located outside and can be easily replaced. In the next-generation Duratec V6, the water pump is built inside, making its replacement very expensive. What to look for when buying a used Ford Fusion: If you want to buy a used Ford Fusion that has been driven in the Rust Belt, have it carefully inspected for excessive corrosion caused by road salt. If the underneath components, such as brake lines or the rear crossmember, look too rusted, avoid the vehicle. Watch out for a burnt oil smell coming from under the hood as it's a sign of oil leaks. Watch out for issues with shifting of the automatic transmission. If some of the shifts feel harsh or happen with a notable delay, avoid the vehicle. Also avoid the vehicle if the brake pedal feels spongy and goes down too low. Ford issued the recall 19V-904 for the Hydraulic Control Unit, which is the main part of the antilock braking system.
Check the NHTSA website for recalls. As of October 2021, Consumer Reports rated the 2007-2009 Fusion as 'average' for reliability, which is a better rating than for other domestic sedans of these years.