Ford and Lincoln vehicles equipped with wired keyless entry keypad systems and accessory wireless keyless entry keypad systems may or may not come with a wallet card containing the master code. Unlike the integrated wired keypad, the accessory wireless keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool or from the label printed on the body control module (BCM). The Factory Keyless Entry Code application within the diagnostic scan tool will not provide an applicable master code for the accessory wireless keypad. If the wallet card for an accessory keypad is not available, the "Wireless RF Keypad Diagnosis Guide" can be referenced and provides direction on how
full bulletin at NHTSA ↗2009 Ford Fusion body problems
severe 31 complaints filed with NHTSA · avg repair $1,500 · see body across all vehicles →
Failure mileage
Complaints
31
Recalls
0
Avg fix
$1,500
7injuries
What stands out
Owners have filed 31 body 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 body 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 driver-side interior door handle is the chronic problem here. Owners say the plastic breaks under normal use—pulling the handle to exit shatters it, leaving them stuck inside and forced to roll down the window and reach outside. This happens as early as the first year and as late as 173,000 miles. Some handles become sharp and cut fingers; others just snap off. The door locks fail too: owners report doors that won't lock from inside or outside, creating security problems on top of the exit problem.
Exterior handles fracture and have sharp edges from peeling coatings. One owner got lacerations on two separate occasions. Passenger-side handles and locks fail the same way, though less frequently reported.
A few owners describe trunk struts that fail, letting the trunk slam down unexpectedly while driving. One reports a rear passenger door latch that won't keep the door closed. Dashboard bulging and deterioration at 32,000 miles shows up in one complaint, with exposed foam and sticky residue near the airbag. Paint chipping and rust appear in isolated cases.
Ford dealers openly told owners this is common and knew about it going back to 2007 models. No permanent recall fix materialized; when a recall notice arrived, parts weren't in stock. Aftermarket replacements are easy to find online, but owners shouldn't have to buy their own safety hardware.
Same Ford Fusion body reports on nearby years: 2007 · 2008 · 2010 · 2011 · 2012
Failure modes owners describe
Driver-side interior door handle fracture/failure
The driver-side interior door handle breaks, cracks, or becomes inoperable, trapping the occupant inside the vehicle. The plastic construction fails under normal use. Owners report the handle becoming so fragile that pulling it breaks the component entirely.
When: Between 32,000 and 173,000 miles; some failures reported within the first year of ownership
Symptoms owners cite: Handle breaks when pulled to exit vehicle; Handle becomes inoperable and door cannot be opened from inside; Plastic handle is sharp or splintering after failure; Occupant must roll down window and reach outside to open door; Handle may hang partially detached by a few pieces
Repairs/costs cited: Door handle replacement; one owner paid over $200 for replacement. Parts are readily available aftermarket online.
Recalls/TSBs owners mention: Ford dealers acknowledge this is a known, common issue. Some dealers refused to acknowledge the problem or provide service. Extended warranty does not cover the failure. NHTSA recall 17V024000 was issued but parts were unavailable at time of complaint.
Driver-side interior door lock failure
The driver-side door lock mechanism fails and the door cannot be locked from the inside or outside. This creates both a security and exit problem, preventing the occupant from securing the vehicle or exiting safely.
When: Between 60,000 and 83,000 miles reported
Symptoms owners cite: Door cannot be locked from inside the vehicle; Door cannot be locked from outside the vehicle; Automatic door lock fails to engage; Warning indicators illuminate showing doors will not work
Repairs/costs cited: Lock mechanism replacement required; exact parts and costs not specified in narratives.
Recalls/TSBs owners mention: Manufacturer was notified in some cases but did not assist or provide resolution.
Exterior door handle fracture/peeling coating
The exterior door handle coating splits and peels, leaving sharp edges that cause lacerations. The handle itself can fracture and break off entirely. The underlying plastic construction is poor quality.
When: Failures reported across various mileage ranges
Symptoms owners cite: Coating over plastic handle splits and becomes razor-sharp; Occupants receive cuts trying to exit vehicle; Handle breaks off in hand; Chrome coating peels severely, creating sharp edges; Handle lacerations occur on two separate occasions for one owner
Repairs/costs cited: Owners replaced handles with parts purchased online; one owner had to tape over handles as temporary fix.
Recalls/TSBs owners mention: No recall available at time of complaint. Ford did not respond to owner requests for recall or reimbursement.
Passenger-side door handle and lock failure
Passenger-side interior and exterior door handles break or become inoperable. The door locks also fail, leaving occupants unable to exit or secure the vehicle.
When: Variable mileage reported
Symptoms owners cite: Interior handle fails to open door; Exterior handle fractures; Door locks become inoperable; Passenger must use alternative exit method
Repairs/costs cited: Handle replacement required; one owner reports passenger side door handle now malfunctioning after driver side was replaced, suggesting pattern of failure.
Recalls/TSBs owners mention: Dealers acknowledge this is a common issue with poor-quality handles.
Dashboard deterioration and bulging
The dashboard on the driver side premature deteriorates, bulges, and shows exposed plastic and foam. A sticky residue expands on the passenger side, exposing the airbag.
When: At approximately 32,000 miles
Symptoms owners cite: Dashboard bulges on driver side; Sticky residue expands on passenger side; Exposed plastic and foam visible near vents on driver side; Airbag exposure due to deterioration
Repairs/costs cited: Not specified; vehicle was taken to dealer for diagnosis.
Recalls/TSBs owners mention: Manufacturer was notified of the failure.
Trunk lid strut failure
One or both hydraulic struts on the trunk lid fail, causing the trunk to not hold its own weight. The trunk lid slams down unexpectedly, creating a safety hazard.
When: Not specified
Symptoms owners cite: Trunk lid will not stay open; Trunk design makes it difficult to close; Trunk pops open while driving at various speeds; Trunk slams down due to failed strut
Repairs/costs cited: Trunk strut replacement needed; dealer did not have parts available at time of complaint.
Recalls/TSBs owners mention: Dealer did not have replacement part in stock; waiting on part delivery.
Rear passenger door latch failure
Rear passenger door latch malfunctions, preventing the door from staying closed. Door opens unexpectedly while driving.
When: Not specified
Symptoms owners cite: Rear passenger door won't stay closed; Door latch malfunctions; Door opened while driving; Door still opens slightly even after being pulled closed
Repairs/costs cited: Temporary fix used: rope to secure door
Paint chipping and peeling
Paint on the vehicle begins to chip and peel prematurely, along with abnormal rust formation on the hood above the grille and inside back doors.
When: At approximately 1,800 miles
Symptoms owners cite: Paint chipping and peeling; Abnormal rust on hood above grille; Rust inside back doors above wheel wells
Repairs/costs cited: Not specified
Synthesized from 31 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had body trouble with your 2009 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 body problem on the 2009 Ford Fusion?
It's a meaningful issue. 31 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,500.
At what mileage does the body typically fail?
Across the 25 complaints that reported odometer mileage, most body failures cluster between 60,000 and 89,500 miles, with the median around 76,000. A quarter of owners report trouble before 60,000; a quarter make it past 89,500. 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 $1,500 for body 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 body?
No active recalls currently cover body 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/2009/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.