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full bulletin at NHTSA ↗2006 Ford Fusion engine problems
moderate 25 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
25
Recalls
0
Avg fix
$3,100
1fire
What stands out
Owners have filed 25 engine 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.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine 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.
The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
full bulletin at NHTSA ↗FORD/LINCOLN/MERCURY: MAY HAVE SLUDGE BUILDUP IN THROTTLE BODY LEADING TO LESS AIRFLOW OR ENGINE IDLING RPM FLUCTUATION AND HARD STARTS OR BATTERY DISCONNECT OR DEAD BATTERY AFTER KEEP ALIVE MEMORY (KAM) CLEAR. MODELS 2003-05 THUNDERBIRD, 05-06 MUSTANG, 06-08 FUSION, 04-05 EXPLORER, 05-06 EXPEDITION, 05-07 F-150; 2003-06 LS, 06 ZEPHYR, 05-06 NAVIGATOR; 06-08 MILAN.
full bulletin at NHTSA ↗POSSIBLE ENGINE DAMAGE - INSTALL SPECIAL SERVICE TOOLS PRIOR TO REMOVING CRANKSHAFT PULLEY BOLT - SERVICE TIP.
full bulletin at NHTSA ↗VERIFY PROPER SERPENTINE BELT AND TENSIONER.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2006 Fusion's engine has a documented pattern of critical failures. Ignition coil failure is the most severe: a coil will fail and take out all other coils, the spark plugs, and the PCM in a cascade at as low as 68,000 miles. Ford TSBs acknowledge this happens before 80,000 miles but warranty coverage ends at exactly that mark or sooner—one owner missed it by 30 days and paid $2,250 out of pocket.
Electronic throttle body failure is widespread and dangerous. The throttle sensor stops responding, engine stalls at idle or highway speed, vehicle enters limp mode capping speed at 20 MPH, and diagnostics can be impossible. Cost runs $600 to over $1,000. One dealer confirmed this is a known issue on Fusions before 2009, yet no recall exists for the 2006 model year.
Engine mount bolts fracture regularly, allowing the engine to drop into the bay. One owner's engine was supported only by the driveshaft at highway speeds on a downtown Atlanta freeway. Early design was faulty; Ford later released a corrected part. Some cars have required six total mount replacements.
Oil leaks, timing chain noise, bearing failures, and thermostat issues also show up. One engine threw a rod despite regular maintenance. A fire occurred at 60,000 miles with parts on backorder. Stalling happens unpredictably at idle and highway speeds with no repeatable diagnostic codes.
Same Ford Fusion engine reports on nearby years: 2007 · 2008 · 2009
Failure modes owners describe
Ignition coil failure with cascade damage
Ignition coil fails and damages other coils, spark plugs, and PCM in the process. Engine misfires and stalls without warning.
When: 68,000 miles in complaint #1; occurs before 80,000 miles per TSB references
Symptoms owners cite: Engine jerking/miss at highway speed; Check engine light; Fluid smell; Engine won't turn over
Codes mentioned: P0303 (Misfire cylinder 3)
Repairs/costs cited: $2,250 repair including coil, all spark plugs, and PCM replacement
Recalls/TSBs owners mention: TSBs acknowledge issue under 80,000 miles/8 years warranty; owner missed warranty by 30 days
Electronic throttle body failure
Throttle body sensor or electronic control unit fails, causing idle drop, stalling, limp mode, or loss of power. No check engine light in some cases. Vehicle can suddenly limit speed to 20 MPH or below.
When: 80,000 miles in complaint #2; 159,070 miles in complaint #13; variable mileage across complaints
Symptoms owners cite: Engine stalls at idle/stop signs without warning; Idle drops below 500 RPM; Engine won't restart immediately; Vehicle enters limp mode limiting speed to 20 MPH; Sudden loss of power at highway speed; No or intermittent check engine light
Codes mentioned: Electronic throttle control warning, Throttle position sensor fault
Repairs/costs cited: $600 to over $1,000 for throttle body replacement; described as common across Ford Fusion models and other Ford models with same throttle body
Recalls/TSBs owners mention: No recalls for 2006 model year; dealer acknowledges issue is widespread on Fusions before 2009
Engine bearing/rod failure
Engine throws a rod or develops bearing failure, requiring complete engine replacement. Occurs after warranty expiration despite regular oil changes and maintenance.
When: Post-warranty failure in complaint #4; under 100,000 miles in complaint #10
Symptoms owners cite: Engine knocking; Low oil level with leaking around oil pan; Loss of power and brake function; Check engine light
Codes mentioned: Diagnostic codes indicate engine needs replacement
Repairs/costs cited: $5,000 engine replacement plus $500 computer part replacement
Recalls/TSBs owners mention: No recall; dealership refused warranty consideration
Engine mount bolt fracture
One or more engine mount bolts fracture, allowing engine to drop into engine bay. Can damage CV boot and create unsafe driving condition. Two different designs identified; early design was wrong and replaced.
When: 5 occurrences reported: complaint #5 at unknown mileage; complaint #21 at low speed; complaint #23 reports all three mounts replaced multiple times
Symptoms owners cite: Engine drops into engine bay; Engine supported by driveshaft touching frame; CV boot rupture; Abnormal creaking sound from front end
Repairs/costs cited: $400 for motor mount and bracket replacement; complaint #5 notes new engine mount, CV boot, and realignment needed; complaint #23 reports six total mount replacements with one replaced three times
Recalls/TSBs owners mention: Ford customer service acknowledged incident but offered no assistance; service tech in complaint #21 confirmed design flaw and installed corrected part same day
Ignition coil wiring system failure
Engine coil wiring harness fails, causing engine stall without warning at various speeds.
When: 122,000 miles
Symptoms owners cite: Vehicle stalls without warning while driving various speeds
Repairs/costs cited: Not repaired per complaint
Stalling and loss of power at speed
Engine stalls unexpectedly during driving at various speeds, sometimes after idle at stop lights. Check engine light may illuminate. Power loss occurs without prior warning. No consistent diagnostic pattern across complaints.
When: Various mileages: 80,000-159,070 miles; occurs at 55 MPH, 65 MPH, and variable speeds
Symptoms owners cite: Engine stalls at highway speed (55-65 MPH); Engine stalls after idle at red light; Check engine light illumination; Sudden loss of power; Engine warning indicator with steering wheel vibration; No restart delay or immediate restart; Rough running before stall
Codes mentioned: P0303 and other misfires, Engine temperature too low codes
Recalls/TSBs owners mention: Unable to diagnose in some cases; manufacturer not always notified
Thermostat stuck open
Thermostat fails in open position, causing engine temperature to run too cold. Owner reports Ford replaced OEM thermostat with higher temperature rated unit, indicating Ford awareness of issue.
When: Complaint #19 does not specify mileage
Symptoms owners cite: Error code for engine temperature too low
Codes mentioned: Engine temperature too low code
Repairs/costs cited: Thermostat replacement; Ford OEM replaced with higher temperature rated unit
Recalls/TSBs owners mention: Ford aware of issue and uses higher temperature rated OEM replacement
Serpentine belt and idler pulley failure
Serpentine belt comes off or breaks; idler pulley bolt breaks off into engine, creating risk of internal damage.
When: Complaint #22 reports idler pulley fracture at 180,000 miles; complaint #24 provides no mileage
Symptoms owners cite: Serpentine belt comes off or breaks; Idler pulley bolt fractures and enters engine
Oil leaks from engine
Oil leaks from engine with origin uncertain. Complaint #4 mentions leak around oil pan. Complaint #10 reports low oil level with leaking around oil pan.
When: 108,000 miles in complaint #17; complaint #4 and #10 at lower mileages
Symptoms owners cite: Oil visible on ground under vehicle; Low oil level; Oil leaking around oil pan
Repairs/costs cited: Mechanic unsure of leak source; not repaired in complaint #17
Recalls/TSBs owners mention: Manufacturer contacted but provided no assistance in complaint #17
Engine fire
Vehicle caught fire without warning while driving. Parts for repair on backorder at dealer.
When: 60,000 miles
Symptoms owners cite: Smoke appeared; Vehicle stalled; Vehicle caught fire
Repairs/costs cited: Parts on backorder
Synthesized from 25 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had engine 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 engine problem on the 2006 Ford Fusion?
It's a documented issue but not catastrophic. 25 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Across the 22 complaints that reported odometer mileage, most engine failures cluster between 70,000 and 98,375 miles, with the median around 80,000. A quarter of owners report trouble before 70,000; a quarter make it past 98,375. 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 $3,100 for engine 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 engine?
No active recalls currently cover engine 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.