Certain 2006-2010 Model Year Fusion/Milan/MKZ/Zephyr Vehicles Equipped with Anti-Lock Brake Systems DOT 3 Brake Fluid and Anti-Lock Brake System Function In some of the affected vehicles, customers may return to the dealer with complaints of extended brake pedal travel after either 19S54 or 20S14 was previously performed and the program is closed
full bulletin at NHTSA ↗2006 Ford Fusion brakes problems
severe 28 complaints filed with NHTSA · avg repair $450 · see brakes across all vehicles →
Failure mileage
Complaints
28
Recalls
0
Avg fix
$450
4crashes
When does it fail?
Of the 28 brakes complaints filed for the 2006 Ford Fusion, here's the actual mileage breakdown — failures cluster heaviest at 75,000-100,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 28 brakes complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
No new NHTSA brakes complaint has been filed on this vehicle in over 9 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering brakes on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The dominant brake issue on 2006 Fusions is the brake pedal dropping to the floorboard with a corresponding loss of braking pressure. Owners describe this as happening intermittently and without warning across a wide range of speeds and mileages (32,000 to 175,000 miles). Some regain braking after pumping the pedal repeatedly or restarting the vehicle; others have experienced near-collisions or actual crashes when braking failed to stop the car in time.
Many of these failures are tied to NHTSA Campaign 19V904000 (Service Brakes, Hydraulic), which targets a faulty hydraulic control unit (HCU). Owners received recall notices as recently as 2019–2021, but dealers consistently reported that parts were not available to complete the repair, sometimes for months. One owner reported that Ford denied his warranty claim despite having only 32,000 miles on the vehicle.
Secondary patterns include ABS-related failures triggered by hard braking on wet or uneven surfaces, soft brake pedals that don't respond properly, and one case of repeated rotor warping requiring multiple resurfacing before replacement. Owners have had mixed results with independent repairs—replacing the master cylinder, brake fluid, pads, and rotors has not reliably resolved the pressure-loss problem. One dealer's brake bleeding provided temporary relief before the issue recurred.
The scope and persistence of these complaints, coupled with recall delays, make this a serious safety concern for prospective used Fusion buyers.
Same Ford Fusion brakes reports on nearby years: 2007 · 2008 · 2009
Failure modes owners describe
Brake pedal drops to floor with loss of braking pressure
The brake pedal unexpectedly depresses to the floorboard, often without warning, resulting in prolonged stopping distance or complete loss of braking ability. Owners report this happens intermittently across varying speeds and driving conditions. Some regain braking after multiple pedal pumps; others experience temporary recovery after restart or remedial brake cycling.
When: Varies widely; reported between 32,000 and 175,000 miles. Often triggered by hard braking, driving over bumps or potholes, or sudden speed changes.
Symptoms owners cite: Brake pedal travels to floorboard without warning; Prolonged stopping distance requiring multiple pedal pumps; Complete loss of braking requiring emergency brake engagement; Braking improves after pumping pedal multiple times or restarting vehicle; ABS engages unexpectedly before pedal loss occurs
Repairs/costs cited: Dealers recommended HCU (hydraulic control unit) replacement, estimated $2,000. Some independent mechanics replaced master cylinder, brake fluid, pads, rotors, calipers, and drums without resolving the issue. One owner temporarily resolved the problem by driving at low speed and slamming brakes repeatedly in a parking lot. ABS replacement resolved the failure in at least one case.
Recalls/TSBs owners mention: NHTSA Campaign 19V904000 (Service Brakes, Hydraulic) issued for HCU replacement. As of complaint dates, recall parts were unavailable or significantly delayed. Ford denied at least one warranty claim related to the recall despite the vehicle having only 32,000 miles at time of denial.
Soft brake pedal with loss of pressure
Brake pedal becomes consistently soft, requiring excessive pressure to achieve normal stopping action. Fluid level remains full, and the issue persists despite independent diagnostic attempts and component replacement.
When: Reported at 138,883 miles; occurring approximately 10–15 times over a 3-month period.
Symptoms owners cite: Brake pedal goes nearly or completely to floor before brakes engage; Requires excessive pedal pressure to slow or stop vehicle; Occurs at various speeds, from city streets to highways up to 60 mph
Repairs/costs cited: Brake fluid level checked and normal. No successful repairs documented in the narrative.
ABS-related brake failure on slippery or uneven surfaces
When ABS engages during hard braking on ice, wet pavement, or uneven road surfaces, the brake pedal either goes to the floor or becomes very soft, creating a momentary loss of braking control. Owners report this particularly happens during emergency maneuvers or at road hazards.
When: Reported across mileage range; typically occurs during hard braking or over rough pavement.
Symptoms owners cite: Brake pedal goes to floor when ABS activates; Soft pedal that nearly reaches floor after ABS engagement; Loss of braking pressure during emergency stops; Occurs when braking over bumps, potholes, or rough intersections
Repairs/costs cited: One dealer bled brakes and reported the issue resolved, but the problem recurred months later. Bleeding alone did not provide lasting fix. One owner found that low-speed brake cycling (25 mph in parking lot, hard braking) temporarily restored normal braking.
Rotor warping or wear requiring repeated resurfacing
Front brake rotors warp or become warped, causing steering wheel shaking during braking. Dealers resurface rotors but the problem recurs within days to weeks. Eventually requires rotor replacement along with pad replacement.
When: Reported at less than 50,000 miles; first resurfacing followed by recurrence within about one week, then again within one month.
Symptoms owners cite: Steering wheel shakes during braking; Vibration in braking system
Repairs/costs cited: Dealer turned (resurfaced) rotors twice at no charge, but problem returned each time. Owner eventually purchased and installed new rotors and pads from independent source.
Recalls/TSBs owners mention: Dealer offered rotor resurfacing at no charge but provided no explanation for the recurring problem.
Synthesized from 28 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
Brake pedal, sometimes, would give, at times going to floor stop,while slowing and or turning on rough intersection areas and exits. My wife told me about this for ~6 months. When I would test drive the fusion, the brakes worked fine. The fusion was repaired at bolton Ford, lake charles, la. On aug. 16, 2016 (97,750 mls.) which entailed changing the mastercylinder and fluid flush. Trouble…
2006 Ford fusion. ABS engaged when having to brake suddenly on ice. The brake pedal went all the way to the floor and was soft after that, going almost to the floor before brakes would engage. Took the car to the nearest Ford garage and was told the hcu was probably out and would cost $2000 to fix it. I told them I needed to think about it. They called back later and said they bled the brakes and…
Had brakes trouble with your 2006 Ford Fusion?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the brakes problem on the 2006 Ford Fusion?
It's a meaningful issue. 28 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $450.
At what mileage does the brakes typically fail?
Across the 18 complaints that reported odometer mileage, most brakes failures cluster between 89,000 and 150,000 miles, with the median around 110,550. A quarter of owners report trouble before 89,000; a quarter make it past 150,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $450 for brakes repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to brakes?
No active recalls currently cover brakes issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Ford/Fusion.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.