The Most Common Ford Fusion Issues You Should Know About

The Ford Fusion is one of Ford’s most well-known vehicles, offering comfort and economy at an affordable price. It is also proving to be one of Ford’s most versatile cars. However, as one of the most affordable of Ford’s lineup during its run, does the Fusion come with a lot of issues? Here are four of the most common problems associated with the Ford Fusion.

1. The Ford Fusion’s transmission shifting problems

A white 2022 Ford Fusion midsize sedan model driving through a metropolitan city
2022 Ford Fusion | The Ford Motor Company

There are a few thousand owner-issued complaints about the Ford Fusion on RepairPal, and over 1,100 of them fall into the “harsh or delayed shifting of automatic transmission” category. According to the findings, 1,151 owners have reported that their Ford Fusion’s automatic transmission developed “shifting concerns.” These reports include Fusion models from 13 model years, with an average mileage-at-incident of around 80,000 miles.

Owners report their automatic transmissions shifting hard, harsh, and with delay. Some also report that the transmission “started revving really high” and wouldn’t “shift to a higher gear.” The cause and cost of these transmission problems vary, with maintenance repairs ranging from software upgrades to the powertrain control module and transmission control module, to replacing the valve body or a complete transmission rebuild.

2. Squeaks, creaks, leaks, and other awful noises of the Fusion

Many owners feel that the Ford Fusion was a bargain for a reason. As mileage builds, owners tend to have more problems with squeaks, creaks, and leaks. There are 472 reports of creaking noises while driving over bumps or turning and 205 reports of transmission oil leaks on RepairPal.

According to these reports, owners start to experience squeaks and creaks around 100,000 miles for various reasons, like a problem with the lower control arms or a strut assembly that needs to be taken apart. There are 10 affected model years reported, and it can cost between $100-$250 to fix.

On the other hand, transmission leaks are reported by owners of both automatic and manual transmission Fusion models of eight different model years. At an average mileage of around 76,000 miles, owners report transmission oil leaking from the left side half-shaft area – a result of a worn axle shaft seal.

3. Issues with the Ford Fusion’s steering

Car Complaints also gathers vehicle owner-reported problems and has plenty of reports for the Ford Fusion. Out of all issues reported across all model years, the worst problem category for the Ford Fusion is steering.

Occurring at an average of around 107,000 miles, owners report power steering not working properly and the power and power-assist steering failing altogether. These problems cost an average of around $1,600 to fix and have been reported most in the 2010-2014 Fusion model years. However, for model years 2014 and above, steering issues have still caused recalls.

4. Swollen lug nuts on Ford models

Surprisingly enough, nearly 300 owners have reported problems with swollen lug nuts on RepairPal. Though not an issue that imposes severe risks to your Fusion or personal safety, swollen lug nuts can be a real pain. According to Ford Problems, the swollen lug nut issue with the Fusion is a direct result of Ford’s design process.

While most lug nuts are just one solid piece of steel, “Ford chose a design that puts an aluminum cap over a steel core. The cap is notorious for swelling and delaminating when it gets hot.” This makes getting lug nuts off the Ford Fusion quite difficult.

Is the Ford Fusion worth it?

While the Ford Fusion does seem to carry a few issues with it, these problems seem to occur more after the vehicle has hit higher mileage. The Ford Fusion still stands as an affordable and decent car that maybe you’ll want to trade in before 100,000 miles. However, if you’re searching for a Fusion in the U.S., you’ll now have to look for a used model.

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