Thinking about buying a used Ford Fusion (2000–2022) in New Zealand? We've documented 11 known faults for this model spanning engine, electrical, body & rust, and transmission. Each researched and verified before it's published. The most serious issues here are rated critical. Two are set out in full below — the rest, with the symptoms, repair costs and checks for each, are free with an account.
11
Documented faults
Critical
Most serious
$800–$3,000
Typical repair
6
Systems covered
Known Ford Fusion faults
Every fault below is documented specifically for this model — researched and verified before it’s published.
01Duratec 2.0 timing chain stretch and tensioner failure
CriticalCommonEngine $1,800–$3,500 to fix
The 2.0L Duratec petrol engine fitted to Mk3 and Mk4 Mondeos develops timing chain stretch and tensioner wear with age, particularly above 150,000 km. A worn chain can skip teeth on the camshaft sprockets, causing misfires, loss of power, and in severe cases catastrophic valve-to-piston contact. The hydraulic tensioner is a documented weak point that loses pressure when oil is degraded.
Symptoms to notice
Cold-start rattling from front of engine that fades after warm-up
Check engine light with camshaft position sensor codes (P0340, P0345)
Rough idle and misfires at idle
Loss of power across the rev range
What to check
Start the engine cold and listen immediately for chain rattle from the front timing cover. Scan for cam/crank correlation codes. Check service history for oil change frequency — neglected oil accelerates tensioner wear.
Where to look: Front of engine, behind timing cover
Ask the seller
“Has the timing chain or tensioner ever been replaced?”
“What is the oil change interval — was it kept under 10,000 km?”
“Any cold-start rattling when you first start the car?”
02Front lower control arm ball joint wear
MajorCommonSuspension $400–$900 to fix
The front lower control arm ball joints on Mk3 through Mk5 Mondeos are a consumable with a typical lifespan of 80,000–130,000 km on NZ roads. The ball joint is pressed into the lower arm and is not separately serviceable on most variants — the entire arm must be replaced. Failure allows the front wheel to shift under cornering loads, causing directional instability and clonking over bumps.
Symptoms to notice
Clonking from the front suspension over bumps and when turning
Vague or wandering steering feel
Uneven tyre wear on the inner or outer front edge
Vehicle pulling to one side under heavy braking
What to check
Inspect the ball joint boot for cracks or grease loss. Check front tyre wear pattern across both sides. If a workshop inspection is possible: Lift the front of the car and apply upward pressure to the tyre at the 6 o'clock position — any vertical movement indicates ball joint wear.
Where to look: Front suspension lower control arm, inboard of front wheel
Ask the seller
“When were the front lower control arms or ball joints last replaced?”
“Any clonking or knocking from the front suspension over bumps?”
“Has the car had an alignment check recently?”
ElectricalMajor
EngineMajor
Body & RustMajor
TransmissionMajor
EngineMajor
EngineMajor
Fluid LeaksMajor
EngineMajor
SuspensionMajor
9 more documented faults on the Ford Fusion
Symptoms, what to check, where to look and what to ask the seller — for every fault above. Free with an account, no card needed. One account covers one vehicle, so make it the car you’re actually looking at.
This page covers the model. Enter the plate of the actual car you’re looking at and see its year, engine, safety rating and register flags — free, no account needed.
Like any used car, it depends on the specific example and its service history. Across the 11 documented faults for the Ford Fusion, the recurring problem areas are engine, electrical, and body & rust. A Ford Fusion with a full service history and no signs of the issues listed on this page can be a sound buy but each one needs to be checked individually before you commit.
What are the most common problems with a used Ford Fusion?
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We've catalogued 11 known faults for the Ford Fusion, covering engine, electrical, and body & rust. Two are written out in full on this page. The rest — with the symptoms to notice, what to inspect, and typical repair costs for each — are free once you create an account.
How much do repairs cost on a Ford Fusion?
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Most single repairs on the Ford Fusion fall between $800–$3,000 at NZ independent-workshop rates. Some of the 11 documented faults cost less and a few cost considerably more, and no one car needs them all. Knowing which ones to look for before you view is what lets you negotiate the price down or walk away.
Should I get a pre-purchase inspection on a Ford Fusion?
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Yes. A Ford Fusion inspection focused on its known weak points is the single best way to avoid an expensive mistake. KickTyres gives you a guided, model-specific inspection plus a market valuation and negotiation figure for $17.90 far less than the cost of missing one of the faults on this page.