Body problems of the 2006 Ford Fusion

29 problems related to body have been reported for the 2006 Ford Fusion. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2006 Ford Fusion based on all problems reported for the 2006 Fusion.

1 Body problem

Failure Date: 05/09/2019

I have already contacted NHTSA, reference # 11119887, I explained that the vehicle was sold to me on January 21, 2017 by al piemonte Ford dealership in illinois. I had no knowledge that the vehicle already had an airbag recall on it and they sold it to me without disclosing this information. They later sent me my first recall notice in the mail 16s26 / NHTSA recall 16v-384 we were involved in a car accident and the airbags did not deploy. When I went to my local Ford dealer, where I was told to go, the Ford dealership informed us that the recall was only for the passenger side not for the driver side airbag. I showed them proof of our accident including pictures from the insurance showing the Ford dealer that neither of the airbags deployed during the accident. We provided proof and paperwork to the Ford dealer. They only replaced one airbag for free and forced us to pay $536. 41 out of pocket. This is our only vehicle and we have a small child. They told us the fact that the driver side did not deploy during the car accident is not there problem and there is nothing that they could do; so we had no other choice, we we're forced to have both airbags replaced. I have an official complaint put in with Ford company, complaint # cas-15888814-t4g1m1 I sent this complaint to their customer relationship center in michigan. I also sent this complaint to the al piemonte Ford in melrose park, IL where the vehicle was originally purchased. I also put in a complaint with the federal trade commission, office of defect investigation complaint #100426513 I have not heard back from anyone! no response back from Ford, no response back from the federal trade commission and no response back from NHTSA. Do you have an update or any status on my complaint? please advise. Thank you, (xxxxx) parts of this document have been redacted to protect personally identifiable information pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

2 Body problem

Failure Date: 07/16/2018

Passenger front door will not open from the inside, but can open from outside drivers side front turn signal does not flash, stays solid. Replaced bulb but does same thing.

3 Body problem

Failure Date: 05/02/2018

Tl-the contact owns a 2006 Ford Fusion. The contact stated the driver's and rear left passenger door failed to open from the inside. The vehicle was not diagnosed or repaired. A local dealer was not contacted. The manufacturer was made aware of the failure but offered no further assistance. The failure mileage was unknown. The VIN was not available. Tw.

4 Body problem

Failure Date: 06/03/2016

I was parking in a bettendort, iowa restaurant parking lot when my car surged forward. I applied the brakes, but car would not stop. It left the parking lot, crossed a sidewalk and went onto a street near an intersection. I kept applying the brakes, but car still wouldn't stop. It collided with an oncoming car, crossed over a median and finally stopped on another street across from the intersection.

5 Body problem

Failure Date: 06/01/2016

Takata recall, body paint horrible, rusted early, transmission went went, electrical system horrible, turns like a truck.

6 Body problem

Failure Date: 12/15/2015

Tl-the contact owns a 2006 Ford Fusion. The contact stated that while driving 60 mph, the driver's door opened while driving. The contact stated that this is a recurring issue. In addition, the contact stated that the air bag light remained illuminated. The manufacturer was made aware of the issue. The failure mileage was 127,000. Ad.

7 Body problem

Failure Date: 08/01/2015

Interior front door latches broke around the 100,000 mileage. All four electric window regulators/motor have failed from the 80,000-110,000 mileage period. Each of the regulators plastic rollers where the cable goes around were broken. Two of the automatic door locks quit working as well. All motor mounts have been replaced at least once and 2 have been replaced twice each. 4-cylinder. I have seen 100's of complaints online about the motor mounts and many for the interior latches and window regulators. I have spent over a thousand dollars on the motor mount issues.

8 Body problem

Failure Date: 07/19/2015

The interior door handle breaks, incase of crash or fire you cannot exit. I was told by the dealer other cars with the same door handle, has them recalled for the same reason.

9 Body problem

Failure Date: 07/10/2015

The contact owns a 2006 Ford Fusion. The contact stated that the foam was protruding from beneath the housing of the air bag. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was 44,000.

10 Body problem

Failure Date: 09/06/2014

Tl-the contact owns a 2006 Ford Fusion. The contact stated after the vehicle was parked, the front driver side interior of the door would not open. The contact stated this was the first time the vehicle experienced the issue. The vehicle was taken to a mechanic where it was diagnosed that the driver side door handle inside needed to be replaced. The vehicle was not repaired and the manufacturer has been made aware of the issue. The failure mileage was 100000. Ss.

11 Body problem

Failure Date: 05/25/2014

The driver's door could not be opened from inside. . . . Had to lower window and reach outside to open the door. I have to do this all the time since this problem started. This is a safety problem in the event I lose power and am unable to open the window in order to open door in an emergency. Exiting is delayed.

12 Body problem

Failure Date: 11/20/2013

When vehicle reaches 65 mph a buffeting of the rear window is so loud that it seems as if it will break . Does not happen all the time. It happens even with the windows raised. I have a blanket stuffed between the rear dashboard and the window to quiet the buffeting. Owners manual refers to the problem and how to remedy it if the windows in the front compartment are down , but nothing if the windows are up. Never had this happen in the past with any vehicle . Very unusual .

13 Body problem

Failure Date: 10/16/2013

I own a 2006 Ford Fusion, and my complaint is about the failure of interior door handles. Three of the four interior door handles will not open the door from the inside of the vehicle, the windows have to be rolled down and the doors opened from the outside. Specifically both front doors, and the left rear door handles do not work. I purchased the vehicle new in 2006. I called the Ford consumer complaint line,and was told that because the vehicle is beyond the 36 month warranty period there was not anything that could be done. Obviously if you can not get out of your car without rolling down the window and using the outside handle; should be a safety issue. I have search online and there numerous complaints with the 2006-2010 years on the interior door handles on online forums, as well as you tube on how to replace them. The spokesperson at Ford said that they do not monitor online forums. They said that would file my complaint with my VIN in their database. You can find the handles on ebay and amazon for about $42. 00. I would appreciate any help that you can give in getting Ford to recognize this as a safety issue and make the repairs to my vehicle.

14 Body problem

Failure Date: 08/24/2013

The contact owns a 2006 Ford Fusion. The contact stated that while driving 25 mph, the passenger and driver's side doors failed to open from the inside. The vehicle was taken to the dealer for diagnosis where it was stated that the door handle needed to be replaced. The vehicle was not repaired and the manufacturer was notified. The VIN was not available. The approximate failure mileage was 100,000.

15 Body problem

Failure Date: 08/12/2013

The contact owns a 2006 Ford Fusion. The contact stated that after parking the vehicle, the driver's side door failed to open. The contact had to open the front window down in order to reach the exterior handle. The vehicle was not repaired and the manufacturer was not notified. The approximate failure mileage was 79,000.

16 Body problem

Failure Date: 06/01/2012

Driver side interior door latch broken. Can not lock car with key fob.

17 Body problem

Failure Date: 05/14/2012

The interior rear door handles have broken. I feel this is a saftey issue in exiting the vehicle, in the event of a crash or fire. I would like to see Ford recall this part so no further issues arise.

18 Body problem

Failure Date: 05/11/2012

I bought my 2006 Ford Fusion on 5/5/12. On 5/11/12 we went to get out of the car & the front passenger door would not shut. You would go to close it & it would just bounce back open. It had something to do with the door striker not aligning up. I had to take it to a Ford dealership to get it fixed. . . $350!! the dealership I bought the car from 6 days earlier would not help us at all!! why in the world would that break on a 6yr old car!! I have a 25yr old car that has no problem opening & closing the doors!! I'm starting to see a trend with this car. Everything everyone else is complaining about with these cars are slowing coming true with my car too. I'm starting to wish I would have never bought this car.

19 Body problem

Failure Date: 05/11/2012

Tl- the contact owns a 2006 Ford Fusion. The contact stated that the vehicle interior door handles on all four doors were broken and as a result, the doors could only be opened from the outside. The vehicle was taken to the dealer who stated that the vehicle was not under warranty and offered no additional assistance. The manufacturer was not notified of the failure. The VIN was not available. The failure mileage was 90,000 and the current mileage was 97,000. Pmb.

20 Body problem

Failure Date: 05/03/2012

The contact owns a 2006 Ford Fusion. The contact stated that the driver's side door handle detached from the vehicle. Prior to the failure, the vehicle also failed to start. The vehicle was towed to the dealer who confirmed that the transmission needed to be replaced. The manufacturer was contacted regarding both failures. The vehicle was not repaired. The VIN was unavailable. The failure and current mileages were 78,000.

21 Body problem

Failure Date: 04/15/2012

The contact owns a 2006 Ford Fusion. The contact stated that she activated the child safety lock on the rear driver's side door and was unable to open it to remove a child from the vehicle. The vehicle was taken to the dealer for diagnosis where the door was repaired. A few months later, the contact attempted to open the driver's side door after parking and was unable to exit the vehicle. A few weeks later, the rear driver's side door failed again. The dealer was notified but offered little assistance. The failure and current mileages were 67,000.

22 Body problem

Failure Date: 03/30/2012

The contact owns a 2006 Ford Fusion. The contact stated that the doors became inoperable. The failure recurred multiple times. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 123,000.

23 Body problem

Failure Date: 03/27/2012

The contact owns a 2006 Ford Fusion. While parked, the contact attempted to open the driver's side door when the interior door handle fractured. The contact could only exit the vehicle by opening the driver's side door window and reaching out to open the door by the exterior door handle. The vehicle was not taken to the dealer for diagnostics. The vehicle was not repaired. The approximate failure mileage was 81,000.

24 Body problem

Failure Date: 02/11/2012

The front interior passenger door handle snapped and now cannot be opened from the inside. This same defect happened to the rear driver side door handle about 1 year ago. This is a major safety issue. We cannot get out of the passenger side front seat without opening the door from the outside.

25 Body problem

Failure Date: 08/01/2011

Tl-the contact owns a 2006 Ford Fusion. The contact stated that over the course of a year, three of the door handles broke. The two rear door handles would still lock, despite not functioning properly. The driver’s side door would not lock. The dealer and manufacturer were both notified, but offered no assistance. The vehicle had not been repaired. The failure and current mileages were 80,000. Sm.

26 Body problem

Failure Date: 08/01/2011

The contact owns a 2006 Ford Fusion. While parked, the contact noticed that the driver side interior door handle was fractured and detached from the vehicle. The contact had to open the driver's side window to open the door from the exterior. The vehicle was not taken to the dealer for diagnostic testing or repairs. The approximate failure mileage was 73,000.

27 Body problem

Failure Date: 06/01/2011

Contact owns a 2006 Ford Fusion. The contact stated that the front passenger and both rear interior door handles became fractured when engaged. In addition, the contact was driving 55 mph when the vehicle failed to respond to acceleration attempts over 55 mph. The seat belt mechanism also failed and the contact was unable to secure the seat belt. The contact took the vehicle to the dealer where the transmission was replaced. The interior door handles and the seat belt were not repaired. The manufacturer was not made aware of the failure. The failure mileage was 55,000.

28 Body problem

Failure Date: 05/05/2011

Early may 2011 I was driving home at 65mph and I lost 5th gear. Then 4th gear. On way to dealership I lost 3rd gear. Warranty covered a brand new transmission. They claim after a week they finally got the transmission in and installed but they were waiting on a part for it because the transmission came with a part for a Mazda 6 and wouldn't work. After two weeks they were finally done. Took vehicle back to dealership on 09/26/2011 stating great difficulty getting vehicle to shift out of park. Also stated there is an excessive amount of heat coming from the console in to the cabin above the transmission. Also stated the transmission is shifting very hard at times. Ford called today and stated the transmission has no problems at all and that I can't get out of park because the shift interlock sylionid needed to be replaced requiring that everything from the shifter and everything below all the way to the floorboard would have to be replaced costing over $400. I have found hundreds of complaints online involving the same issues. This is a major safety issue.

29 Body problem

Failure Date: 05/13/2009

The interior door handles have broken on three of the four doors and require you to open them from the outside to exit the vehicle. This is a systemic problem with Ford Fusions with inferior plastic door handles.


Other Structure related problems of the 2006 Ford Fusion


Safety Ratings of Fusion Cars
Fuel Economy of Fusion Vehicles
Fusion Service Bulletins
Fusion Safety Recalls
Fusion Defect Investigations