One problem related to transfer case has 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.
Vehicle is a daily drive, experienced TSB 13-4-17, pcm failure causing the ignition coils to burn out on cylinder 4. Vehicle was towed to Ford dealership, where vehicle was repaired, at a cost of over $2000. Immediately after the vehicle had a howl and vibration, vehicle was taken to a local mechanic and diagnosed as a transfer case (ptu) failure, this was a few days after leaving the Ford dealership. My local mechanic replaced the ptu at a cost of $1000. Vehicle was fine from November 2013 till just this past week March 6 2014 where a leak of gear oil was found in the driveway, car was brought to local Ford dealership which confirmed a leak of the seal on the transfer case (ptu). Vehicle has been brought to local mechanic that made the repair. I find it unbelievable that since this vehicle has hit 100k miles that it is in need of constant repair. I have owned many Fords and have never had an issue like this. After much research I have found that these are common problems!! Ford needs to do something about this!! they claim to have reliable vehicles but this is not reliable, especially since I bought this car as a certified pre-owned from a Ford dealership in July of 2010 I only got 3 good years out of this vehicle. Its a shame cause its such a beautiful car and now I have nothing but mechanical issues.