The 2009 Fusion is a solid mid-size sedan undermined primarily by its 6F35 automatic transmission, which develops internal failures and cooler leaks between 80k-150k miles. The 2.3L I4 has catastrophic piston failure issues rare but devastating when they occur, while the 3.0L V6 is considerably more reliable.
Symptoms: harsh 2-3 or 3-4 shifts or flaring between gears, shuddering on acceleration from stop, transmission slipping under load, coolant mixing with transmission fluid (strawberry milkshake fluid), coolant loss with no external leaks
Fix: Internal clutch pack wear and direct clutch failure are the main culprits requiring rebuild or replacement (8-12 hours labor). The internal cooler in the radiator fails, allowing coolant and ATF to mix, necessitating radiator replacement, full fluid flush, and often transmission replacement if contamination circulated long (10-14 hours total)
Symptoms: sudden catastrophic knocking noise, metallic rattling on cold start that worsens, loss of compression in one or more cylinders, metal shavings in oil, check engine light with misfire codes P0301-P0304
Fix: The 2.3L suffers from piston skirt cracking that leads to complete engine failure. Requires short block replacement or full engine rebuild with updated pistons (18-24 hours labor). Many owners opt for used engine swaps instead of rebuild
Estimated cost: $3,500-$5,500
Passenger-Side Transmission Mount Failure
Common · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: heavy clunk when shifting from Park to Drive or Reverse, excessive vibration at idle in gear, visible engine movement when revving in Park, banging noise over bumps
Fix: The hydraulic transmission mount on the passenger side deteriorates and fails. Replacement is straightforward but requires supporting the engine (2-3 hours labor). Should be done with OEM or quality aftermarket, not cheap eBay mounts
Estimated cost: $250-$450
ABS Module / Pump Failure
Occasional · high severity
Typical onset: 90,000-140,000 mi
Symptoms: ABS and traction control lights illuminated, brake pedal pulsing during normal stops (not just ABS events), extended stopping distances, loss of power assist feel, codes C1145 (pump motor circuit) or C1095 (hydraulic pump)
Fix: The ABS hydraulic control unit develops internal failures, particularly pump motor or solenoid issues. Requires module replacement and brake system bleeding (2.5-3.5 hours labor). Ford issued recall 14S32 for some units but not all years/VINs covered
Estimated cost: $1,200-$1,800
3.0L V6 Valve Cover Gasket & Ignition Coil Issues
Common · low severity
Typical onset: 80,000-130,000 mi
Symptoms: oil seepage visible on valve covers, burning oil smell from engine bay, oil pooling in spark plug wells, intermittent misfires, check engine light codes P0351-P0356
Fix: Valve cover gaskets leak oil into spark plug tubes, fouling coils. Both valve covers need gasket replacement plus any damaged coil-on-plug units (3-4 hours labor). Preventive replacement of all six coils recommended when doing gaskets
Estimated cost: $600-$900
EVAP Purge Valve & Fuel Tank Vent Valve Failures
Occasional · low severity
Typical onset: 70,000-120,000 mi
Symptoms: check engine light with P0455 (large EVAP leak) or P0443 (purge valve circuit), difficulty refueling (pump clicks off repeatedly), rough idle after refueling, fuel smell near tank area, failed emissions test
Fix: The purge valve (mounted on engine) and fuel tank pressure sensor/vent valve both stick or fail. Purge valve is easy (0.5 hours), but fuel tank vent valve requires dropping tank or accessing through trunk (2-3 hours labor)
Estimated cost: $200-$550
Owner tips
Change transmission fluid every 50k miles with Mercon LV only—never go to 'lifetime' fluid claims
If buying a 2.3L I4, verify compression test results and listen carefully for cold-start knock
Inspect transmission cooler lines and radiator for any signs of cross-contamination immediately if coolant level drops
Replace transmission mount proactively around 80k miles to prevent damaging halfshafts and CV joints
V6 models are significantly more reliable than I4—worth seeking out if shopping used
Buy the 3.0L V6 variant only, avoid the 2.3L I4 entirely, and budget $3k-4k for an eventual transmission rebuild or replacement—otherwise a decent highway cruiser.
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.
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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 · 18V046000
2018-01-11 · EA15001
Ford Motor Company (Ford) is recalling certain 2013 Ford Mustang vehicles sold, or ever registered in the states of 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, Ford is recalling certain 2010 Ford Edge, Fusion, Mustang and Ranger, Lincoln MKX and Zephyr/MKZ, and Mercury Milan vehicles ever registered in the states of 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."
Ford is also recalling certain 2009 Ford Edge, Fusion, Mustang and Ranger, Lincoln MKX and Zephyr/MKZ, and Mercury Milan vehicles 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 or "Zone C."
These vehicles are equipped with air bag inflators assembled as part of the passenger frontal air bag modules, used as original equipment or replacement equipment (such as after a vehicle crash necessitating replacement of the original air bags), that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and 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: 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. 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 · 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.
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