In this article, I am going to go over the most common problems with the first-generation facelift (CD3) Ford Fusion which was produced from the year 2010 to 2012.
Fortunately, from my experience as a mechanic, these are reliable vehicles but not without their share of problems.
I have put together a list of the most common issues that I have come across in this article; let’s get to it.
2010-2012 Ford Fusion Brief Overview
The Ford Fusion is a mid-size car produced by the Ford Motor Company. It was first introduced in 2006 and received a facelift in 2010, which is what I will be discussing here.
The Fusion is available with a variety of engine options, each catering to a different level of performance needs. With various engine options to choose from, the Fusion caters to diverse performance requirements.
Starting with a four-cylinder 2.5L engine, it generates a robust 175 horsepower.
Those seeking more power may opt for the 3.0L V6 engine, delivering a potent 240 horsepower. For those desiring peak performance, the Fusion offers a 3.5L V6 engine, producing an impressive 263 horsepower.
Not forgetting the eco-conscious driver, the Fusion also comes with a hybrid option: a 2.5L 4-cylinder engine capable of outputting 191 horsepower.
These engines can be paired with either a 6-speed automatic or 6-speed manual transmission, providing flexibility for diverse driving preferences
2010-2012 Ford Fusion Common Problems
Now let’s look at the common issues with the first gen facelift Ford Fusion.
1. AC Problems:
The biggest issue with these cars is the air conditioning (AC).
Many owners have said that the Air Conditioning sometimes doesn’t work right.
When they try to get cold air, it gives out hot air. After a while, it might go back to normal.
But sometimes, it does the opposite and blows cold air when it’s set to hot.
Luckily, this is not a serious issue and can be fixed by taking the car to a mechanic when it happens.
2. Valve Cover Gasket Leak:
Even though the engines in this generation of Ford Fusion don’t tend to burn oil.
They have been known to develop Valve cover oil leaks, especially in models with higher mileage.
The Valve Cover Gasket, a seal positioned between the engine and the valve cover, plays a crucial role in preventing oil leakage.
However, with time and use, this gasket may deteriorate, leading to potential oil leaks.
While the valve cover gaskets themselves aren’t particularly expensive, the labor involved in replacing them can add up.
Nonetheless, for those with some mechanical knowledge, this is generally a straightforward repair job.
3. Interior Door Handles:
The Interior door handles can come off prematurely. This is a common problem for many cars but seems to be worse in the Fusion.
The handles themselves are not of great quality, which leads them to break over time.
Owners have reported that the inside door handle has fallen off or broken on them multiple times.
Again this can easily be fixed by yourself should it happen.
4. Power Steering Rack Failure:
The biggest problem seen with Ford Fusion cars made between 2010 and 2012 is that the power steering rack often breaks.
In fact, Ford had to recall some models because of this issue.
The power steering rack helps make the wheels of your car turn when you turn the steering wheel.
When it breaks on a Fusion, a “service advancetrac” message shows up, and the steering wheel becomes much harder to turn.
I’ve had a few Fusions in my shop with this problem, so it seems to be common.
This issue usually happens in Fusions that have been driven a lot (Higher Mileage), so it’s something that happens over time.
In this case, you will need to have the whole steering rack replaced.
5. Lug Nuts Swell
The Fifth and final common problem that I’ve seen on the Fusion is the lug nuts swelling up.
These are the nuts that hold your wheels on, and if they swell up, it can cause problems when trying to remove the tire.
The factory Lug nuts on these vehicles are prone to swell.
The best way to avoid this problem is to make sure that you change your lug nuts when they start to show signs of swelling.
Ford Fusion Reliability
Now that I have gone through the common problems that I have seen with these vehicles let’s talk about their reliability.
In general, I’ve seen that this generation of Ford Fusions are very reliable vehicles.
They are not prone to any major issues, and most of the problems that come up are minor in nature.
The 2.5L engine is pretty much bulletproof. On average, I would say that these vehicles have an average of 200,000-300 000 miles on them before they start to show signs of wear.
Additional Sources
https://carbuzz.com/cars/ford/fusion-generations
https://www.yourmechanic.com/estimates/ford/fusion/valve-cover-gasket-replacement
https://www.copilotsearch.com/posts/ford-fusion-years-to-avoid/
https://www.cars.com/research/ford-fusion/recalls/