hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
93,000 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2006 Ford Fusion body / paint problems

body / paint problem

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2006 Ford Fusion Owner Comments

problem #8

Oct 042010


  • 45,000 miles


I have a 2006 Ford Fusion. I bought it used just a year ago, and shortly after it started making a little bit of a popping sound when turning. I knew there had to be something wrong with it. It eventually got worse making a loud creaking sound whenever I would turn, push the gas, and hit the breaks while going a lower speed. We took it in to be looked at, and they didn't see anything wrong. Then we went somewhere else, and they miss diagnosed it. Finally, we went to a Ford dealership and found out it was a cracked subframe. Ford would not cover the cost of fixing it, so we emailed Ford to complain and they still would not do anything. I plan on writing complaints anywhere I can. This problem can be dangerous, and they don't seem to care. Are they waiting for someone to get hurt first. It sounds like there should be a recall for this.

- Clinton, UT, USA

problem #7

Nov 082010


  • 51,000 miles
The contact owns a 2006 Ford Fusion. The contact was driving approximately 38 mph when she heard a noise coming from the steering column. The vehicle was taken to an authorized dealer and the mechanic advised her that the sub frame would need replacing. The vehicle was not repaired. She then called the manufacturer and was advised that the sub frame was not a warranty issue and would not provide any further assistance. The failure mileage was 51,000 and the current mileage was 53,027.

- Plainfield, IL, USA

problem #6

Oct 042009


  • 320,000 miles
The contact owns a 2006 Ford Fusion. The contact stated that the vehicle began to make a clicking noise whenever the vehicle was turned left or right. The vehicle was taken to an authorized dealership where she was informed that the subframe was corroded and was not safe to drive long distances. The subframe was replaced at the contacts expense. The clicking noise continued so the contact took the vehicle back to the dealership; however, the dealer could not diagnose the failure. The cv boot was replaced but the problem persisted. The contact filed a complaint with the manufacturer. The current mileage was approximately 36,000. The failure mileage was approximately 32,000.

- Greenville , NC, USA

problem #5

Apr 192010

Fusion 4-cyl

  • 75,000 miles


2006 Ford Fusion SE with 2.3L I-4 engine. 75,000 miles. Two bolts on left engine mount fractured causing engine to fall into engine bay. Engine fell on and is being supported by the drive shaft which is touching the frame of the vehicle. This caused the cv boot to rupture. Car is unsafe to drive with such a failure. Fortunately this happened in my driveway. Had it happened only 10 minutes before, it would have occurred on I-20 in downtown atlanta at rush hour and would have likely caused an accident. Called Ford customer service and they took a record of the incident but were not helpful beyond that. I need a new engine mount, new cv boot, and everything under the engine to be realigned.

- Atlanta, GA, USA

problem #4

Aug 172009


  • 56,000 miles
There is a creaking noise from the front end of the car, which appears to be a crack subframe in my 2006 Ford Fusion SE V6. There is a technical service bulletin (tsb 06-24-7) for the 2006 Ford Fusion, 2006 zephyrs and 2006 Milan. It states that the repair is eligible under provisions of new vehicle limited warranty coverage. My car is still under this warranty, and Ford (fette Ford, clifton NJ) has refused to aid me in any way. I purchased my vehicle from sawgrass Ford (sunrise, fl). They claim this is not under warranty, and are trying to charge $2100 for the repairs. This is a dangerous situation and hazardous to one's life, because the cracked frame affects the steering control of the car.

- Wayne, NJ, USA

problem #3

Aug 092009


  • 56,000 miles
I own a 2006 Ford Fusion that started have a clicking noise while driving straight or making right or left hand turns or even backing up. I took into my mechanic to look at and he call to tell me it was a cracked frame, and that he located a service bulletin by Ford with reference to my Fusion and the Milan having a crack in the frame and that they make a repair kit available that requires the subframe to be dropped and holes drill with bolts and rivets along with a plate to fix the problem. I check both Ford and your web site for a recall and found nothing. These crack can lead to a frame failure and an accident with possible injuries or death.

- Clemmons, NC, USA

problem #2

Jun 012009


  • 48,000 miles
One of the welds on the subframe of my 2006 Ford Fusion cracked. When it happened my car had less than 50,000 miles on it. I took it in to rodeo Ford who diagnosed the problem and is now trying to charge me $1500 to have it welded back. They tried to reassure me however that my car was safe to drive. I contacted Ford customer care who told me they would not work with me to fix the issue. My warranty was up in January 2009 and Ford customer care told me there were no other warranties I could purchase to help with the repair. This is obviously an issue with many 2006 Ford Fusion and Ford themselves should make the repairs at no cost to the consumers. This is Ford faultiness, not the consumer's and something really needs to be done about it.

- Richardson, TX, USA

problem #1

Apr 072009


  • 93,000 miles
4/7/09 I went to the dealership because of noise coming from front end when turning or going over bumps on my 2006 Ford Fusion and was told that it had a cracked subframe. I spoke with the manufacturer and was told too bad as it is out of warranty. The dealer has been notified by the manufacturer that this is a problem and they were told how to weld it so that it would be fixed. The dealerships mechanic told me it was nothing I did, there was no signs of impact. He said it was something that Ford was having a problem with. A car this new should not have a cracked frame and according to the mechanic it is an issue with Ford who is ignoring this safety issue.

- Northwood, NH, USA

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