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Common problems with the Ford Fusion include transmission issues, swollen lug nuts, oil leaks, CD player failure, check engine light staying on, key getting stuck in the ignition, etc.

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The 2013 second-generation Fusion was shown at the 2012 North American International Auto Show. Fusion was an example of Ford's global car strategy, "One-Ford," with a design built by Ford of Europe.

Ford's new mid-size platform remerges in Europe and the Americas with the newest version of the CDW27 program, which originated from the Ford Contour/Mercury Mystique. 

Common Problems

The most common problems with the first generation Ford Fusion are: 

  • Oil leaks. Typically from the valve cover or transmission oil pan. 
  • Swollen lug nuts that are hard to remove. 
  • Radio stops working
  • Check engine light on
  • Key getting stuck in the ignition
  • Trunk not closing 

Let's take a look a deeper look at these issues: 

Transmission Shifting Issues

Transmission issues in an automatic transmission may be resolved by updating its PCM and TCM with newer software. The updates can be particularly useful on lowered-mileage vehicles. As miles add up, the internal transmission itself often disintegrates. Rebuilding the transmission valve body or installing a complete replacement unit could help.

If major transmission repairs are made, it is important to continually update the PCM and TCM with the latest software, to prevent these problems from happening in the future.

Oil Leaks

Ford Fusion Common Problems

A common problem that affects the Ford Fusion is oil leaks which in most cases is going to originate from the valve cover. To fix this problem the valve cover gasket needs to be replaced. 

For help with this issue see this guide on how to replace the valve cover gasket on Ford 2.5L engine

Alternator

Ford Fusion Problems

The battery may die on you when driving down the road and the battery light indicator flashes on the dashboard due to a bad alternator.

The alternator is located on the backside of the engine and it’s very tricky to replace. Access it from underneath and you will still have to remove several components. The four-cylinder engine is easier to repair than the V6. 

Lug Nuts 

Ford Fusion Problems

Fusion owners complain of the lug nuts actually swelling and some of that is due to corrosion. There are little caps over the lug nuts, and when that happens, it’s hard to get the socket onto the lug nuts to be able to remove them. This happens on other vehicles, but it’s very common on Ford Fusion.

The recommended repair for this is replacing the lug nuts.

Ignition Switch

Ford Fusion Lug Nuts

When you put the vehicle in park, you can’t take the key out of the ignition. The shifter assembly itself, the internals may wear out or get damaged. Ignition switch may need to be replaced.

Power Steering Fluid Leak

When you’re going down the road and you’re turning the wheel and hearing a whining noise, that’s probably because your power steering is low. A damaged hose could probably end up causing a leak. The power steering pump is located on the passenger side. 

The Ford Fusion uses MERCON V which is automatic transmission fluid.

Water Pump

Ford Fusion Problems

If coolant is leaking from the engine, behind the AC compressor, or behind the alternator, this is a typical sign that the water pump must be bad. The weep hole right behind the alternator allows coolant to leak out. If there is a problem with the water pump in this vehicle, it must be driven by timing change.

If coolant is present in this area, it’s most likely the water pump and it needs to be replaced.

If you are looking to buy a used Ford Fusion you should consider fuel economy and safety ratings as well.   

Fuel Economy 

Ford Fusion Consumption
Source: fueleconomy.gov

Safety

Ford Fusion Safety
NHTSA Crash Test Results

If you own a Ford Fusion, we have published many repair guides on this model to help you save money on car maintenance.