Front Suspension Coil Spring Problems of Ford Fusion

Backed out of garage and noticed left front of hood was lower than right side. Found a broken spring on left front strut assembly. When replacing the left front spring, I found that this was actually the 2nd break on that spring, the other break was heavily rusted, so had happened long before. The new break was approximately 1 coil farther up the spring. When I removed the right front strut assembly, I noticed that spring was also broke and had been for a long time as well. Both springs were broke in almost the exact same spot, right where the spring is no longer supported by the lower spring seat. It appears that this would be a heat treat issue with the springs and there would be many people with the same issue. I did have a coworker with the same breaks on her Mercury milan, same model year. Multiple dealership visits did not notice the breakage, but did notice an alignment issue, not surprising. Assemblies are still in my possession. I have attached a picture of the right side spring, you can see the amount of rust on and around the break and also see the break is at the end of the lower spring seat.

See all problems of the 2012 Ford Fusion 🔎.

Front passenger side coil spring over the wheel found borken. Had to replace the coil spring. Shop suggested replacing the strut as well, and also told us that this should ba a mold problem and had happened to a lot of Ford, chevy, and 07-09 Honda, but Ford never issued a recall. There happens to be a chevy truck next to us with a broken coil spring.

See all problems of the 2011 Ford Fusion 🔎.

October 14, 2015 replaced both front coil springs (broke near the top). I know that one or both of them broke when I was backing out of my driveway onto the street and turning the steering wheel to start down the street. That was the only time that I heard a loud noise like a spring breaking and started to hear a rubbing sound a short time later, which I was told was the broken spring rubbing against the tire.

While parked in my garage, the car made a very loud bang. I looked at the car to find the front drivers wheel way up into the fender well. I thought it might have been a broken ball joint. Once the car was lifted, I found the coil spring had snapped, just sitting there!! I also found that it had been broken in two spots as on one break it was rusted and the new break was fresh. My family drives the car a lot and I am so thankful that it happened in my garage, we could have been killed!! I am off now to see how much this is going to set me back. I think this is a safety issue that Ford should address and that others should know about.

See all problems of the 2010 Ford Fusion 🔎.

I have a 2006 Fusion this problem started a year ago. First my car shakes, when driven 20mph and try to accelerate it has a hard time picking up speed it misses. So I had my spark plugs changed twice in the last year because I thought that's what was wrong. I took it to my local good year and they noticed that I've had my spark plugs changed with them twice so, the mechanic took my car apart and found that my 5th cylinder was bad and that it was burning through my coils. 2 years ago I had issues with my balls joints on my car front tires fixed it now, I am having the same problem my ball joints have clay in them how that happen I don't know. There is also a 3rd problem that I am having with my transmission. I came across this website to see if there were any recalls for my vehicle, of course it would be my luck nothing!!! I work for Toyota and they recall their vehicles all the time for any issue they have with their vehicles. I will never buy a Ford again!!!.

See all problems of the 2006 Ford Fusion 🔎.