Ford’s short-lived midsize sedan had a reputation for reliability, which makes it a good option as a used car. We review its model years and consider the best pre-owned Fusion vehicles.
The Ford Fusion was in production from 2006 to 2020, making it a teenager in age, but it was a certainly grownup challenger to competitor sedans in the midsize class. The Fusion had a design that echoes aspects of Aston Martin, and it was built by one of the industry’s top automakers.
However, the Ford Fusion car lived–and died–a short life in comparison to some of its competitors. But its reputation for reliability has made it a good option as a used vehicle or as a Ford Fusion rental car.
In fact, the Fusion often landed on reputable “Best Used Cars” lists, including those by Consumer Reports and iSeeCars.
It was produced for two generations with front-wheel drive and all-wheel drive (on select trims), and it’s had a myriad of different drivetrains all with specific goals in mind. A short 14-year stint of making Fusions does not mean Ford wasn’t met with problems, recalls, or the crushing weight of the SUV market.
During its tenure though, the automobile was rugged and reliable enough to be used as a Ford Fusion race car in 2013, and later it was adapted as police vehicles.
The Ford Fusion cop car launched in 2017 and was dubbed the Ford Police Responder Hybrid Sedan. It was one of two hybrid police vehicles the company released, and the industry’s first-ever pursuit-rated hybrid vehicle. The Fusion’s affordability also reportedly saved the NYPD quite a bit of money.
However, if you’re in the market for a pre-owned Ford Fusion, you should know that not all model years have the same reliability rating. And there are some years that you should cross off your shopping list altogether. Let’s break down the short-lived life of Ford’s midsized sedan.
Are Ford Fusions Good Cars?
The Fusion was well-equipped and had strong initial sales. In its first year, Ford saw 145,502 sales for the Fusion plus the 16,983 sold at the end of the 2005 year, when the new 2006 Fusion was released.
Those sales numbers hovered around 140,000 units for a few years and only moderately improved for the 2009 facelift with 180,581 Fusions sold. While respectable, it paled in comparison to the surge after the 2010 refresh.
With the body changing so much and powertrains becoming more attractive, Ford broke the 200k barrier and blasted into the 300k club in the following years.
In 2014, Ford sold 306,860 Fusions, which represented its mountain top. Sales have been dwindling since that model year and barely capped 100,000 in 2020, as the Fusion prepared for the big sleep.
While the Fusion didn’t stay on top for long, market trends are not lost on the resourceful and wise auto manufacturer. Ford has pivoted into the SUV market as the trend for SUVs continues to extend its roots for most American drivers.
So, is the Ford Fusion a good car? All things considered, the Ford Fusion is a good car, which makes pre-owned options something to consider if a quality sedan is what you’re looking for as a used-car buyer.
However, some Fusion model years are better than others, and some should be avoided altogether because not every model year of every vehicle always hits it out of the ballpark. Sometimes, recalls, complaints, common problems, and other issues factor in to make one model year less recommended than another.
Notably, although it’s the last run for the model, the 2020 Ford Fusion has a high-reliability rating for a midsize sedan according to both auto experts and the Fusion owners, putting it in the top 10 of J.D. Power’s Consumer Rated Sedans class with a reliability rating of 87 out of 100.
Vehicle History‘s real-owner reviews of the latest Ford Fusion also show a favorable response, with the sedan garnering 4.54 stars out of a total of five. Our expert reviews from professional auto critics gave the Fusion 4.10 out of five stars.
By using the database at the National Highway Traffic Safety Administration, the extensive knowledge base here at Vehicle History, and expert and customer reviews and complaints, we’ve compiled this article to tell you everything you need to know about the reliability and recalls related to the Ford Fusion and what model years to avoid because of too many recalls, complaints, or other issues.
Cars similar to the Ford Fusion include the Volkswagen Passat, Hyundai Sonata, Subaru Legacy, Chevrolet Malibu, Kia Optima, Nissan Altima, and Mazda Mazda6. And when compared side-by-side, the Fusion holds its own quite well in regard to MSRP, standard features, and reliability
First-generation Ford Fusion
From 1974 to 2015, Ford was a part-owner of Mazda, and as a starting point for a new sedan, after the Ford Contour was retired, the Blue Oval enlisted the versatile Mazda G platform chassis as the foundation of this new vehicle. Ford’s CD3 platform was used by Mercury, Mazda, and Lincoln for different vehicles as a proven chassis.
The first-generation Ford Fusion came with a handsome three-bar grille design and sweeping body panels that indicated a clear upgrade in sophistication.
“For Fusion, we wanted a visible, efficient design,” Ford’s V.P. of Design, J. Mays, told Wards about the 2013 Ford Fusion, which he revealed was styled to appear more expensive than it is and represented the new face of Ford. “It sends a strong signal [as an] aspirational vehicle.”
Aspirational, indeed. For most of its run, the Fusion remained a fresh and friendly face for Ford’s midsize-sedan segment. The vehicle came in three trims: S, SE, and SEL. The S trim came with a Duratec 23, 2.3L I4 with a choice of a five-speed manual or five-speed automatic transmission.
The powertrain was good for 160 horsepower. If you had extra money in your pocket, you could spring for an SE or SEL trim that opened the possibility to the Duratec 30, a 3.0L V6 with 221 ponies.
2007’s ‘Fusion Challenge’
In late-2006, Car and Driver hosted a “Fusion Challenge” that was later rebranded into the “Ford Challenge” and launched as a major promotional campaign by the Blue Oval. The idea was that Ford would test its mettle against Japanese car manufacturers that were dominating the midsize segment at the time.
Using a closed course in Washington D.C., Ford arranged for over 600 real consumers to drive a 2007 Honda Accord EX-L V6, a 2007 Toyota Camry XLE V6, and a 2007 Ford Fusion SEL AWD V6 on a closed course.
Then, they rated each car based on what they thought. Out the gate, it was no surprise that Honda and Toyota were on top, but once consumers drove the Fusion, the playing field was leveled.
It was notable how well the Fusion drove in comparison to the more established and seemingly better vehicles. The Fusion wasn’t just a trick up Ford’s sleeve to shave away at some of the competition. It was all-out aggressive elbowing to claim their seat at the table, and it was working.
Car & Driver also tested the Ford Fusion again in 2010, pitting it against a Mazda 6 and Honda Accord. The Fusion again held its own, and although it was not the top-rated in the 2010 challenge, it did prove competitive and reliable in the challenging road test courses.
Ford Fusion Changes & Refreshes
From 2007 to 2009, the Fusion continued to receive bolt-on updates that made the average consumer’s life a little better. The upgrades included Sirius Sat-Radio, more airbags for safety, auxiliary jacks, tire pressure monitoring, ambient lighting, and optional electronic stability control.
The trim levels stayed the same, other than a Sport Appearance package touting 18-inch wheels, a spoiler, stiffer suspension, and other cosmetic changes.
Also available was a Moon and Tune package that gave you a moon roof and a high-tech audio system for the windows-down-music-up consumers.
By 2010, Ford had squeezed most of the juice out of the Fusion and was setting its sights on a facelift. The new model got considerably updated front and rear body styling with interior refreshes as well.
Most importantly, the powertrain also received an update to the sound of a 2.5L inline-four and a 3.0L profile ignition pickup (PIP) V6 –– which was also used in the Ford Escape debut at the time. These engines would be mated to Ford’s new 6F35 six-speed transmission and produced 175 horsepower and 240 horsepower respectively.
Along with the new powertrains, Ford retained the same trim levels as before and added two more of note. Tacked on to the SEL trim was a Hybrid trim that employed the same 2.5L inline-four with assistance from an Atkinson hybrid-electric motor. This gave the Fusion better gas mileage and even an introduction of the Eco Driving Mode, which would inform the driver of how good (or bad) they were driving in regards to fuel mileage.
Fusion Sport
Also added, and intentionally saved for last, was the Fusion Sport. This was a standalone trim that turned the performance and styling up a couple of notches with 18-inch wheels, a blacked-out grille, lower rocker panels, and even a rear spoiler to insist the rear end stay down when flying down the drag strip.
Other bits that mattered were the 3.5L V6 pushing out 249 horsepower and a sport-tuned suspension. While it may not win many races with its 0-60 just over six seconds, it wasn’t a slouch and everything above made it a great package for someone who wanted the best of all worlds. Unfortunately, safety concerns unfolded after that.
Ford Fusion’s Second Major Update
With the 2010 refresh out of the way, Ford was prepared to release what it had really been working on –– and it was not auxiliary jacks. The 2013 Ford Fusion revamp looked like something designed by Aston Martin itself, and it marked the dawning of a new era for the iconic automaker.
With an aggressive stance, familiar grille, and luxury-like accompaniments, Ford was making a statement, and the Fusion was becoming a force to reckon with.
The second-generation Fusion came equipped with MacPherson struts up front and a multi-link rear suspension, which differed from the first-gen double wishbone suspension setup. The trunk lost a little bit of space comparably despite the car’s size increasing overall.
For this generation, the trim levels were S, SE, and Titanium, losing the SEL name from yesteryear. Ford had been trying to push out the Duratec 30 (3.0L V6) and they used this new Fusion as another nail in its proverbial coffin by offering only four-cylinder engines and dropping the Sport model altogether. Feel free to gasp.
While the Sport model would come back in 2017 with a 2.7L EcoBoost V6, the offerings were adequate in 2013 with choices that ranged from a familiar 2.5L, 1.6L Turbo, and 2.0L Turbo.
These engines were all mated to a six-speed automatic transmission and even came with paddle shifters for the race car driver in all of us. By the time it was all said and done, Ford had a total of five engines for the second-generation Fusion, including two hybrid variants.
Safety Technology
Sometime around 2013, technology in automobiles began advancing rapidly and capitalizing on driver assistance in the name of safety. Ford didn’t miss this boat either, and the Blue Oval packed the Fusion with all the latest tech available at the time.
Utilizing sensors, cameras, and radar, Ford incorporated Lane Keep Assist, Adaptive Cruise Control, and Forward Collision Warning.
Plus, they also added Active Park Assist and Blind Spot Information System, which alerts the driver to traffic in their blind spot.
Also worth mentioning, the Fusion was now equipped with electric power-assisted steering that allows the vehicle to make quick maneuvers without upsetting the chassis too much.
Ford Fusion Recalls & Safety Issues
2006-2012: Takata Airbag Recall
Ford Motor Company was one of many auto manufacturers affected by the widespread Takata Airbag Recall that affected 2006-2012 Ford Fusion vehicles.
2006-2010 Model Years: Brake Pedal Interference
The Fusion’s first-year model saw only five recalls in America, including for airbag safety issues and a floor mat that interfered with the brake pedal.
Also, there is a safety recall in Canada only for select 2006 to 2010 Ford Fusions. In some affected vehicles, a normally closed valve inside the hydraulic control unit may stick open, which could result in extended brake pedal travel, potentially increasing the risk of a crash.
2013-2016 Model Years: Shifter Cable Bushings May Detach
In 2018, Ford issued a safety recall in North America for approximately 550,000 2013-2016 model year Ford Fusions to replace shifter cable bushings. On affected vehicles, the bushing that attaches the shifter cable to the transmission may detach from the transmission.
A degraded shifter cable bushing that detaches from the transmission may allow the transmission to be in a gear state different than the gear shift position selected by the driver. The condition could allow the driver to move the shift lever to “Park” and remove the ignition key, while the transmission may not be in “Park,” with no warning message or audible chime.
If the parking brake is not applied, a degraded shifter cable bushing that detaches from the transmission could result in unintended vehicle movement, increasing the risk of injury or crash. However, Ford reports that it is not aware of any accidents or injuries related to this issue.
Affected vehicles include:
- 2014 Ford Fusion vehicles built at Flat Rock Assembly Plant between June 18, 2013 and Sept. 15, 2013
- 2014-2016 Ford Fusion vehicles built at Flat Rock Assembly Plant between June 2, 2014 and Aug. 31, 2015
- 2013-2014 Ford Fusion vehicles built at Hermosillo Stamping and Assembly Plant between May 15, 2013 and Sept. 15, 2013
- 2014-2016 Ford Fusion vehicles built at Hermosillo Stamping and Assembly Plant between June 2, 2014 and Aug. 31, 2015
The recall involves approximately 549,401 vehicles, including 504,182 in the U.S., 36,887 in Canada, and 8,332 in Mexico. The Ford reference number for this recall is 18S20. Dealers will replace the shifter cable bushing at no cost to the customer.
2014-2016 Model Years: Latch Susceptible to Cracking
A safety recall regarding 2014-2016 Ford Fusions was announced in early 2020. Ford Motor Company issued the recall because affected vehicles have a latch pawl spring-tab design that is susceptible to cracking and failure in areas with high temperatures.
Also, there is a potential the door may unlatch while driving, increasing the risk of injury.
Ford has reported that it is not aware of any reports of accident or injury related to this recall. This action affects 248,912 vehicles in the U.S., 19,431 in Mexico, and four in Canada.
Affected vehicles include:
- 2014-2016 Ford Fusion vehicles built at Flat Rock Assembly Plant and Hermosillo Assembly Plant, Nov. 1, 2013, to April 27, 2014
Affected vehicles are or have been registered in Alabama, Arizona, Arkansas, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, Oklahoma, Oregon, South Carolina, Texas, Utah, and Washington. Dealers will remove and replace the side door latches. The Ford reference number for this recall is 20S15.
The Ford Fusion’s second generation had the highest recall number, with the 2013 model racking up 17 recalls, noted by the U.S. Department of Transportation. The recalls address issues like doors unintentionally opening and detached shift cables causing the car to roll away while shifting into park.
However, as each year passed, the Ford Fusion’s recalls dwindled to almost nothing. This could be because the recalls for more current models are not surfacing just yet, but the trend seems to be that the later models are more sorted.
Which Model Years Should You Avoid?
While it can seem a bit like an obvious answer, when digging into the history of the Fusion we found that it wasn’t so simple. One might think that you should just choose the new model, and there is merit to that. Especially if you’re a person that enjoys creature comforts, more technology, and lower miles.
If that describes you, our recommendation is that you avoid the 2013-2014 model year. Ford sold the most Fusions in 2014, but they also had the highest number of recalls and complaints.
While there are certainly people with 2013 and 2014 Fusions that don’t experience these problems, it’s not a lottery we recommend playing.
For the commuter with technology and modern style on the brain, we recommend the 2015 to 2020 model.
If you’re looking for a more affordable option and you’re going to purchase a first-generation Fusion, you should avoid the 2010 Ford Fusion.
While we really like the refresh that Ford did with this model year, it came with 13 recorded recalls, while the 2006 and 2007 years only had five apiece. The styling is going to be a bit older, but the Duratec engines last forever with proper maintenance and there’s far less to worry about in terms of manufacturing defects left unfixed by previous owners.
The earlier model years are more suited for the driver that wants to do their own maintenance or purchase a starter car for a new driver.
Conclusion
The Fusion lived a short and interesting life, including being selected as Ford’s car for NASCAR, replacing the Taurus, in 2006. Also interesting, the Fusion teamed up with Roush Racing to set a world land speed record for the fastest ground speed car using a fuel cell.
The driver was none other than Rick Byrnes, retired Ford engineer and notable Bonneville racer, and he pushed the Fusion down the salt flats at 207.297 mph in August 2007.
In 2010, the Fusion won Motor Trend’s coveted Car of the Year award against multiple competitors, and the 2010 Fusion Hybrid won Best Car of the Year at the Detriot Auto Show.
Our point? The Fusion was and is a good car with countless accolades and plenty of evidence to back up such a claim. Ford still knows how to build ’em.
Photos: Ford
