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Ford Fusion/Mercury Milan Maintenance & Repair



  • at 4800 miles had trans, flywheel and clutch replaced. the alignment pins from the flywheel had broken off and went through the trans, caused a nice oil leak on my friends driveway. (actually clutch fluid). talked with some ford engineers and said there had been only a few other cases of this happening with early fusions and that the cause was improper installation.

    also noticed that the side airbags in the seat where not that great of fit, I can see the airbag itself

    other than that the car is great, good quality, the body lines are good,
  • mschmalmschmal Posts: 1,757
    Dealers have to follow the service requirements from Ford. Ford says to turn the rotors when pads are replaced, dealers have to do so.

    I was told that the rotors have to be turned so that they wear in the pad right?

  • well yes you turn a rotor to fix the out of round condition and the parallelism, plus it does help a new pad wear, and makes the rotor all smooth and a non-directional finish.

    also its one of those things that if your doing pads then you should do rotors at the same time

  • Is it hard to remove the console?
  • chenlpuchenlpu Posts: 1
    This is a brand new Fusion 08 SE and engine service and transmission service lights are on. We took car back to dealer and they said that some rodent just bite wires under the hood. Such thing is not covered by warranty and we have to pay it.

    It is interesting that our neighbor's Fusion was attacked by squirrels too (told by the same dealer). I am wondering whether this is a design problem from Ford or not ?

  • blumsteinblumstein Posts: 38
    Yes, it is. Ford didn't realize at the time of the car's creation that the word "fusion" just happens to mean "diner" in rodent language.

    You'll notice that there are no complaints from Milan owners on this problem.


    {PS: This is an early April Fool's Day post}
  • elkeinelkein Posts: 19
    I just bought a fusion SEL AWD, in the manual it state that the AWD system is zero maintenance and sealed. I take that to mean it should last to 250K or so without changing the oil. I'd only worry about it if it pee's on the driveway someday, or develops noise.
  • 1lowmilan1lowmilan Posts: 1
    Take your vehicle to the dealer they have an advisory concerning this problem and it will be fixed for free. It takes about 40 minutes...
  • vvbusymomvvbusymom Posts: 1
    Our 2007 Fusion with 23000 miles on it has just burnt up it's clutch. The dealer says it is not covered by the warranty and wants $1300 to fix it. Has anyone had any similar problems? We are not new to manual transmissions and find it hard to believe we did anything to cause this.
  • Can anyone recommend how to remove the drivers side door panel? I need to remove it to replace a busted side view mirror.

  • akirbyakirby Posts: 8,040
    Take out the screws around the perimeter (2 or 3 I think) and the one inside the door pull hole, then gently pry the panel off (on second thought I don't think you can be too gentle - those clips are pretty strong). I think one or more of the screws require torx bits.
  • Thanks for the quick response. I purchased what I believe is an aftermarket replacement mirror. Do you think the back cover will switch out easily from my old mirror to my new. Do you see a downside with purchasing the aftermarket mirror.

  • akirbyakirby Posts: 8,040
    No idea. Sorry.
  • Hey there vvbusymom,

    We had our clutch go at around 20,000 miles also, it was around $1,500 to replace. The car now has 44,000 miles on it, and the darn clutch is gone again!
    Both my wife and I have had manual transmission cars all our life, and we have never had to replace any clutch in any car we ever had.

    Plus, it's not like we are teaching teenagers to drive on it. We know how to drive a stick the right way. No racing, riding the clutch, etc.....

    There is obviously a problem with the Fusion's Clutch. I am trying to resolve this with Ford now. I will keep you posted as to the outcome. I am going to try and "get back" the $1,500 I already paid, and obviously, the current repair as well.

    Just a word of advice - the clutch WILL die on you again.......

  • There could be several reasons for early wear, the clutch material being a likely culprit. If that is the case, perhaps using an aftermarket replacement may yield longer life.
  • Thanks for the advice. Just got off the dreaded phonecall with Ford - of course they say that we wore the clutch out (again). This is truly ridiculous.

    My wife is furious, and calling the dealer right now. I would hate to be them right now :P

    The only other thing I can do is go the BBB route (Lemon Law is no good because I bought it used with 6,000 miles). My experience in the past with the BBB is not giving me warm fuzzies though. I'm afraid we are going to eat the $1,400 or so to fix it, though we will continue to fight the good fight until we are out of options. I will update this post as things progress, or don't progress; either way.

    One thing that is certain though - we are not going to keep a car that needs a new clutch every 20,000 miles. I will literally drive it off the Ford lot and straight into the Toyota Dealer down the road. Hopefully I don't burn the clutch out on the way there.
  • akirbyakirby Posts: 8,040
    Have you gotten other quotes? That seems really high for just a clutch replacement. 20,000 is too soon but from Ford's standpoint unless a defect can be identified in the clutch material or clutch engagement then it's just normal wear. It doesn't take much abuse to wear out a clutch in 20,000 miles. Not saying you are abusing it but that's not out of the ordinary.

    I would have the clutch engagement and material checked by an independent shop. If you can find a defect take it back to Ford. You could also try a heavier duty clutch material.
  • I had the exact same thing happen. You're lucky they replaced the clutch for you. Ford refused to do this for me, even after talking to Ford Customer Service. It's not a great idea to put a used, fluid-soaked clutch in a car receiving a new flywheel and transmission.
  • I just had this TSB (transmission fix/replace) done on my 2006 Mercury Milan Premier V6, 1.5 weeks prior to warranty end. The dealer service wouldn't do it until the car hit 20K as per TSB. I didn't know it was transmission related until now. When I brought it in a few weeks ago I only had 19800 and they just reset the computer and said bring back after 20K. Problem started happening when cruise control engaged, going around 60+ mph, accelerating with foot or Set +/-, then decelerating with Set +/-, car would thump, bang, RPM's go to 3-4+, sounded like it was going to blow. Then it kept happening after turning cruise control off. Had to accelerate gradually. This went on for months. Now wondering if engine is damaged. Service said they "opened up" transmission. TSB says transmission control assembly replaced. Also, last week, yellow check engine light came on, service says it was gas cap leak evaporation but not related to this TSB.

    This is a lease and both it and warranty expires Fri 1/16/09. My buyout price is $13000 and I will have to buy an extended warranty. (I paid in $12K already). If I buy and trade in, only get $11K. To buy equivalent car/mileage - $14500 so once I give up this car couldn't buy similar for $13K. Now car rides great on highway, never sounded and felt so good, but only tested a few days. Gas mileage can go 30 on highway but usually 12-16 around local S. Florida.

    While gas is cheap now, it already is moving higher. This car gets worse city mpg than my previous Mercury's though replacing 2 OEM Pilot tires with high performance Michelin ones helped a few mpgs at 10K miles.

    I don't want to lease or buy new. I was thinking of getting a used Hyundai Elantra :blush: just for the much better mileage, but for $13000 I'd be getting a 2007 with 20K+ miles but at least would have some warranty left. I can extend the lease a month or two but would only make sense if I was to buy this car. I haven't bought used in years so kinda leery.

    Is this car now worth buying for $13K? Or is this car tainted & now prone to have more problems with the transmission? :lemon: According to this, , this problem can damage the whole transmission, but Ford makes you wait until 20K miles to fix it! I have no idea how bad the tranmission might really be, service isn't saying. Ford warranties this repair for 12 months/12K miles but not sure if that includes the whole transmission they looked at or what parts.

    Since I'm a first year owner, no prior history avail so don't know what other problems await for this car. This 2006 just missed when Ford lengthened the powertrain warranty later that year.

    Any opinions appreciated. I noticed in Consumer Reports that 2007-8 Milans don't show this problem as much, or maybe it doesn't show up until later.

  • berriberri Posts: 7,969
    I think your buyout is way too high for an 06 Ford product (they depreciate pretty quickly). You may be able to negotiate something more realistic (under $10K). However, my experience with Ford vehicles is that the ones that started with problems didn't get better with time and all of them started having problems around 50-60K. I think I'd move on. I've seen ads for new 09 Camry's well equiped at $18,900 and I understand Toyota is about to improve the incentive. I think you can get a new 09 Ford Fusion for less than $15K well equipped where they have to make room for the new improved 10's coming in shortly.
  • akirbyakirby Posts: 8,040
    You need to read more. It's not 1990 anymore and the Fusion has better reliability than the Camry. This was an isolated incident (as you can tell by the small size of this forum). The Fusion has been rock solid as have all of the new Fords.
  • berriberri Posts: 7,969
    We'll see as more of them hit 60K and up. I hope you're right but D3 have a mixed record at higher mileage and the Fusion hasn't been out that long. Taurus has only been average, Explorer below average. I'm concerned about their constant cost cutting impact on their parts durability. You screw the vendors, they'll make their money some way or fold. In any event, the buyout price is still way high for an 06. He can get a new Fusion for just a few grand more than they want for him to keep the current car and a Camry for another few grand. Not sure how depreciation will play out and which will cost less over time.
  • akirbyakirby Posts: 8,040
    That's a loaded V6 model - you can't buy a new one anywhere close to that price. The OP even said a comparable used model with same mileage is $14,500. So $13K is not a bad price.

    I've driven several Ford products past 60K with no problems at all. This isn't 1990.
  • explorerx4explorerx4 Central CTPosts: 12,039
    not sure what model you have, but i have an SEL. it has a black plastic triangle shaped piece with a tweeter in it just above the door panel.
    i grabbed it by the top of the triangle and in just pulled away from the door.
    didn't pull it completely away from the door, my mirror is still ok :), but give it a try before you try taking off the whole inside door panel.
    2017 Ford Fusion SE 2014 Ford F-150 FX4
  • explorerx4explorerx4 Central CTPosts: 12,039
    let me see if i have this right, you had your car for three years and have 20k miles on it.
    there is A post on the site you linked to that this could cause damage long term.
    some things to consider:
    search the web for a ford factory extended warranty. select lots of years, low mileage. 7/75 or something like that. some dealers sell these online.
    i you get to the point where you want to keep the car, negotiate with the finance person on the warranty, using the web quote.
    is the cost of the warrany worth the money for how long you expect to keep the car?
    i'm not sure why you bought new tires already.
    considering you gas mileage, it sounds like a lot of stop and go/city driving,
    if you don't keep the car, get a 4 cyl next time.
    2017 Ford Fusion SE 2014 Ford F-150 FX4
  • berriberri Posts: 7,969
    That's a loaded V6 model - you can't buy a new one anywhere close to that price. The OP even said a comparable used model with same mileage is $14,500. So $13K is not a bad price.

    Maybe at a Ford dealer, but I think if he was trading he'd have a hard time getting $13K. It's 3 years old and despite the low miles, most 3 year old cars lose over half their value. I've driven both the V6 and 4 versions of the Fusion. The original 3.0L V6 doesn't give you that much of a performance edge over a 4 cyl Camry or Accord. The 4cyl is noticeably worse and despite its smaller size it delivers worse mileage than the Camcord. I trust that Ford is speaking the truth when it says the 2010 models will give better performance and mileage because I'd welcome some real competition from Detroit for a change. With all the deals and low financing out there, I think the guy is making a mistake spending that much on a 3 year old common sedan.

    PS - D3 quality lags are much more recent than 1990 unfortunately, although CR does give the Fusion high marks, but it is an exception on D3 - 3 year reliability.
  • explorerx4explorerx4 Central CTPosts: 12,039
    so, what do you drive?
    2017 Ford Fusion SE 2014 Ford F-150 FX4
  • berriberri Posts: 7,969
    Used to drive Ford and GM, but too many problems moved me over to Honda and Toyota. Get lots of different ones as rentals though. But honestly, I wouldn't buy a 3 year old camcord either for the difference ratio to new cars today. Plus, slow business means even lousier trades right now. If he wants a Fusion or Milan, I'd go new, longer term I think he'll make out better.
  • explorerx4explorerx4 Central CTPosts: 12,039
    how long ago did you own a ford or gm?
    show some pride in your stuff on carspace.
    mine is out there. :P
    2017 Ford Fusion SE 2014 Ford F-150 FX4
  • Hi all, Is the current DOHC V6 in the Fusion the same DOHC V6 that the 97-99 Taurus had in them? I have that engine in my 98 Taurus and it's got 140,000 and still going strong. What new changes are going into the 2010 Fusion that are differant than the current Fusions? Thanks.
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