The 2008 Fusion is a solid mid-size sedan undermined by catastrophic transmission oil cooler failures and questionable I4 bottom-end durability. The V6 holds up better, but the CD3 platform's Achilles heel is that cooler mixing ATF with coolant.
Symptoms: Milky/strawberry-colored transmission fluid or coolant, Transmission slipping, delayed engagement, or complete failure, Overheating transmission or engine, White smoke from exhaust if coolant enters trans
Fix: Replace transmission oil cooler, flush both cooling system and transmission multiple times, often requires transmission rebuild or replacement if contamination ran long. 8-15 hours labor depending on trans damage.
Estimated cost: $1,200-4,500
2.3L I4 Bottom-End Failure (Piston Ring Land Cracking, Rod Bearing Wear)
Occasional · high severity
Typical onset: 100,000-150,000 mi
Symptoms: Excessive oil consumption (1 qt per 500-1,000 mi), Rod knock on cold start or under load, Metal shavings in oil, low oil pressure warning, Blue smoke from exhaust
Fix: Short block replacement or full rebuild with pistons, rings, bearings, and machine work. 16-22 hours labor. Often more cost-effective to swap in used engine (8-10 hours).
Estimated cost: $3,500-5,500
Rear Transmission Mount Collapse
Common · low severity
Typical onset: 70,000-110,000 mi
Symptoms: Clunk on acceleration or deceleration, Vibration at idle in Drive, Excessive driveline movement visible from underneath
Fix: Replace rear transmission mount, sometimes center torque mount while you're there. 1.5-2.5 hours labor.
Estimated cost: $180-350
ABS Module Failure
Occasional · medium severity
Typical onset: 90,000-130,000 mi
Symptoms: ABS and traction control warning lights, Loss of ABS function, Pump motor runs continuously or not at all, Hard brake pedal or reduced braking assist
Fix: Replace ABS hydraulic control unit or have module rebuilt by specialist. Requires bleeding entire brake system. 2-3 hours labor.
Estimated cost: $800-1,400
Fuel Filter Clogging (High-Mileage Units)
Occasional · medium severity
Typical onset: 120,000+ mi
Symptoms: Hard starting, long crank, Hesitation or stumble under acceleration, Stalling at idle or low speed, Check engine light with fuel trim codes
Fix: Replace inline fuel filter. Often overlooked because it's not in the maintenance schedule but should be done every 60k on these. 0.8-1.2 hours labor.
Estimated cost: $120-220
Takata Airbag Inflator Recall (NHTSA)
Common · high severity
Symptoms: No symptoms until deployment, Inflator can rupture sending metal shrapnel into cabin
Fix: Check VIN at NHTSA.gov for open recalls. Driver and passenger inflators affected. Dealer replacement is free, 1-2 hours per side.
Estimated cost: $0
Owner tips
Check transmission fluid color every oil change — catch cooler failure early and you might save the trans with a $1,200 repair instead of $4,500
If buying a 2.3L I4, demand oil consumption test or walk away — these engines either burn nothing or a quart every 800 miles
Change fuel filter at 60k and 120k even though Ford says 'lifetime' — it's a $40 part that prevents $800 fuel pump replacements
Run the VIN for Takata airbag recalls before purchase — some still haven't been fixed 6+ years later
Buy the 3.0L V6 if you find one with service records showing the trans cooler was addressed; avoid the 2.3L I4 unless you can verify no oil consumption issues.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
Fitment notes: Standard top post battery; located in engine compartment
As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.
Control Modules — 2008 Ford Fusion
Every control module on the 2006-2012 Ford Fusion — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
⚠️ PATS function integrated in PCM. Key programming requires dealer tool and security access.
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE · 21V158000
2021-03-10 · EA15001
Ford Motor Company (Ford) is recalling certain 2007-2011 Ranger, 2006-2012 Fusion, Lincoln Zephyr, Lincoln MKZ, 2006-2011 Mercury Milan, 2007-2010 Ford Edge, and Lincoln MKX vehicles. The driver's side air bag inflator may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will replace the driver-side airbag inflator or module with an alternate one, free of charge. Owner notification letters were mailed on April 9, 2021 for the passenger side, and November 14, 2022 for the driver side. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S12.
AIR BAGS:FRONTAL · 21V081000
2021-02-16 · EA15001
Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S05.
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:CONTROL UNIT/MODULE · 19V904000
2019-12-18 · EA18002
Ford Motor Company (Ford) is recalling certain 2006-2010 Ford Fusion, Mercury Milan, Lincoln Zephyr and MKZ vehicles. The valves within the ABS Hydraulic Control Units (HCU) may react with brake fluids containing specific corrosion preventative additives. This reaction may cause the valves to not close properly.
Consequence: If the valves do not properly close, additional brake pedal travel may be required to stop the vehicle, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will flush the brake system with DOT 4 fluid and install a new brake fluid reservoir cap. In addition, the HCU will be tested to detect a possible stuck valve condition, replacing the HCU as necessary. All services will be performed free of charge. The recall began April 1, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S54.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 17V024000
2017-01-10 · EA15001
Ford Motor Company (Ford) is recalling certain 2012 Ford Fusion and Mustang and Lincoln Zephyr and MKZ vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A."
Additionally, unless included in "Zone A" above, Ford is recalling certain 2009 Ford Ranger, Edge, Fusion and Mustang, Lincoln MKX, MKZ and Zephyr and Mercury Milan vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia and West Virginia, or "Zone B."
Additionally, unless included in "Zone A" or "Zone B" above, Ford is recalling certain 2007-2008 Ford Ranger, Edge and Lincoln MKX, 2006-2008 Ford Fusion, Mercury Milan, Lincoln Zephyr and MKZ, 2005-2008 Ford Mustang and 2005-2006 Ford GT vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin and Wyoming.
These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the passenger frontal air bag, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Interim letters informing owners of the recall and that parts are not yet available began mailing March 1, 2017. Owners will receive a second notice when remedy parts become available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S01.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 16V384000
2016-05-31 · EA15001
Ford Motor Company (Ford) is recalling certain model year 2007-2011 Ford Ranger vehicles, 2006-2011 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2007-2010 Ford Edge, Lincoln MKX vehicles, 2005-2006 Ford GT vehicles, and 2005-2011 Ford Mustang vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A."
Additionally, unless included in "Zone A" above, Ford is recalling certain model year 2007-2008 Ford Ranger, Edge and Lincoln MKX vehicles, 2006-2008 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2005-2006 Ford GT vehicles and 2005-2008 Ford Mustang vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia, or "Zone B."
Any vehicle not included in "Zone A", or "Zone B" is not included in the safety recall.
These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Ford mailed interim letters informing owners that parts are not yet available on July 15, 2016. Owners will receive a second notice when remedy parts become available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 19S01.
EQUIPMENT · 14E028000
2014-05-29 · EA12009
Ford Motor Company (Ford) is recalling certain all weather driver side accessory floor mats sold for use in model year 2006-2011 Ford Fusion and Mercury Milan, 2006 Lincoln Zephyr, and 2007-2011 Lincoln MKZ vehicles manufactured November 9, 2007, through October 31, 2010. The affected floor mats may move and possibly interfere with the accelerator pedal.
Consequence: The floor mat could shift such that it could interfere with the accelerator pedal, preventing its return to an idle position, which could result in unintended vehicle speeds, increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will install new replacement mats, free of charge. The recall began in July 2014. Owners may contact Ford's customer service at 1-800-392-3673. Ford's number for this recall is 14S07. NOTE: Vehicles built after October 31, 2010, while potentially equipped with the same floor mats, are equipped with a Brake Over Accelerator (BOA) feature that prevents simultaneous accelerator and brake application, allowing the vehicle to be safely stopped by pressing firmly and steadily on the brake pedal.
Vehicle Info — 2008 Ford Fusion
Performance
Horsepower
221hp
Torque
205lb-ft
Fuel economy (EPA)
City
18mpg
Highway
26mpg
Combined
21mpg
Fuel
Regular Gasoline
Capability & size
Seating
5seats
EPA class
Midsize Cars
Wiper blades
Sedan body style has no rear wiper. Both front wipers are same length.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2008 Ford Fusion 3.0L V6 Duratec and can vary by trim.
🔧 Built by master technician Chris Hackleman · Master Technician · 20+ years.