Two problems related to battery cable have been reported for the 2007 Ford Fusion. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2007 Ford Fusion based on all problems reported for the 2007 Fusion.
The dash panel on my 2007 Fusion suddenly lit up - oil light, air bag light, etc. - and after stopping the car it would not start again. The battery cables (especially the positive one) were highly corroded. After removing the corrosion and replacing the battery it started. Five weeks later it failed to start again. Both times the radio and lights worked but the car would not start. I tried jumping it off, but it did not even try to turn over. Had it towed to the dealership and they said the battery cables and 20 feet of cable wire were completely corroded and would have to be replaced. The car has fewer than 48,000 miles on it. I do not live in a high salt area either. Apparently this is not under warranty either. I believe that substandard equipment was used and that there should be a notice sent out to other Fusion owners to take any precautionary steps to avoid this – if there are any. Ultimately, I think Ford should cover this repair. It is clearly due to shoddy cables and wiring.
The 2007 Ford Fusion developed erratic electrical power and starting failure. Dealership found that the battery cables had essentially disintegrated from battery posts along considerable length of the cables, also destroying the battery with excessive corrosion and splitting the plastic cable sheaths. Vehicle was only 2 years old but had 42,000 mi. A quick internet search immediately found 3 other 2006-2007 Fusions with same occurrence, all just slightly over the 36,000mi warranty and not covered. Ford has not issued a TSB, has not volunteered to cover any of the $428 cost. This is a clear quality control product failure, unacceptable on any 2-yr-old vehicle, and could have resulted in a fire or stranding situation.