Ford2000–2022 Critical issues documented

Ford Fusion MA: common faults & what to check

The MA is the Ford Fusion built 2007–2015. Of the 11 faults documented for the Fusion, 5 apply to this generation, each with its symptoms, what to inspect and a typical repair cost. Free, no account needed.

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Documented faults

Critical

Most serious

$800–$3,000

Typical repair

Systems covered

You're looking at the MA

Everything below is narrowed to this variant. Pick a different one to change it.

2007–2015MA Selected2007–2015MAEngine not documented for this generationEngine not documentedDocumented issues5 knownSee faults & what to checkPhoto: No machine-readable author provided. M 93 assumed (based on copyright claims). via Wikimedia Commons, CC BY-SA 3.0.

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Now narrow it to the engine

A 1.8 and a 2.4 of the same car do not fail the same way, so the faults below narrow to the engine as well as the year. Free, no account needed.

A 2007 Ford Fusion is the MA generation (2007 to 2015).

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Ford Fusion MA

Can't confirm for this car

Ford Fusion · 2007

Narrowed to the year. No engine is recorded for this vehicle. Pick an engine to see which faults apply.

Tell us the engine, or check the engine code on the car, before relying on this.

No engine is recorded for this vehicle.

matched on year only

What to look out for

The checks worth doing on a Ford Fusion before you hand over any money. Every documented fault is listed below, each with its own page.

Costly issue
Inspect the ball joint boot for cracks or grease loss.
See why
Front lower control arm ball joint wear
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.
What you would 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
Typically $400–$900 to put right.

See all 5 issues for this oneDocumented for the exact year and engine you picked, including 1 rated critical.

Body, brakes, suspension & interior1

01Front lower control arm ball joint wear

Inspect the ball joint boot for cracks or grease loss.2000–2022Suspension$400–$900

CommonSuspension $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

Parts involved: Ball joint.

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?”

Depends on the exact engine — 4 moreDocumented for a specific engine we could not confirm from what you picked. Check the engine code on the car.

Engine, transmission & cooling3

01Duratec 2.0 timing chain stretch and tensioner failure

Start the engine cold and listen immediately for chain rattle from the front timing cover.petrol2000–2014EngineCan't confirm for this car$1,800–$3,500

CommonEngine $1,800–$3,500 to fix

Can't confirm for this car

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

Parts involved: Timing chain.

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?”

02Dual-mass flywheel failure on TDCi manual transmission

With the engine idling in neutral, depress the clutch and listen for a rattle or rumble that disappears when the pedal is released.diesel2000–2014TransmissionCan't confirm for this car$1,600–$3,200

Very commonTransmission $1,600–$3,200 to fix

Can't confirm for this car

Manual TDCi Mondeos use a dual-mass flywheel (DMF) to dampen diesel vibration, which wears between 100,000 and 180,000 km. A worn DMF produces a rattling sound when the clutch is depressed, harsh vibration at idle in gear, and clutch judder on take-up. The DMF is replaced together with the clutch kit as a package, making it a significant repair. This is one of the most consistently documented failure modes for manual TDCi Mondeos across owner forums in both the UK and AU markets.

Symptoms to notice

Rattling or rumbling when the clutch pedal is fully depressed
Vibration through the gearstick and floorpan at idle with the car in gear
Judder on clutch take-up from rest
Clunking noise when moving off slowly in first gear

What to check

With the engine idling in neutral, depress the clutch and listen for a rattle or rumble that disappears when the pedal is released.
Rock the car forward and backward in gear with the clutch partially engaged to feel for judder.
Request clutch replacement records.

Where to look: Between engine and gearbox, inside the bellhousing

Parts involved: Clutch.

Ask the seller

“Has the clutch or flywheel been replaced?”
“Any rattling noise when pressing the clutch pedal?”
“Do you notice vibration at idle when the car is sitting in gear?”

03TDCi EGR valve carbon fouling and failure

Scan for EGR flow and position codes.diesel2000–2022EngineCan't confirm for this car$600–$1,400

Very commonEngine $600–$1,400 to fix

Can't confirm for this car

Both the QJBA 2.0 TDCi (Mk3/Mk4) and the later 2.0 TDCi (Mk5) suffer heavy carbon accumulation in the EGR valve and intake manifold from low-speed urban driving. Fouling restricts flow, causing rough idle, power loss, and black smoke. The EGR valve actuator also fails electrically. This is one of the most widely documented fleet issues across Ford diesel platforms and is exacerbated by the short-trip duty cycles common in NZ and AU cities.

Symptoms to notice

Rough idle that worsens when the engine is warm
Hesitation and surging under light throttle
Black smoke from exhaust at idle or under acceleration
EGR-related fault codes (P0400, P0404, P0405)

What to check

Scan for EGR flow and position codes.
Check the intake manifold inlet for carbon buildup visible through the air inlet tract.
If a workshop inspection is possible: Inspect the EGR valve body for carbon clogging — this may require removing the valve.

Where to look: EGR valve mounted on intake manifold, passenger side of engine

Parts involved: EGR valve.

Ask the seller

“Has the EGR valve been cleaned or replaced?”
“Is this vehicle used mainly for short city trips or longer highway runs?”
“Any smoke from the exhaust on startup or at idle?”

Fluid leaks1

01TDCi high-pressure fuel injector copper seal failure

With the engine running, listen for injector ticking and inspect each injector's entry point to the cylinder head for carbon deposits or sooting.diesel2000–2014Fluid LeaksCan't confirm for this car$800–$2,200

CommonFluid Leaks $800–$2,200 to fix

Can't confirm for this car

The 2.0 TDCi injectors are retained with a clamp and sealed at the cylinder head with copper washers. These washers compress and harden over time, causing combustion gases to leak past the injector. The resulting carbon build-up seizes the injector body to the head, making removal extremely difficult and risking thread damage to the aluminium head. This is a well-documented and progressive failure mode across the Ford TDCi range.

Symptoms to notice

Sharp metallic ticking from the cylinder head, worsening under load
Diesel or exhaust smell inside the cabin
Black sooting or carbon deposits around the injector body at the head surface
Rough idle and misfire on the affected cylinder

What to check

With the engine running, listen for injector ticking and inspect each injector's entry point to the cylinder head for carbon deposits or sooting. An oscilloscope injector test or return-flow measurement will confirm imbalance on a faulty injector.

Where to look: Top of the cylinder head, one injector per cylinder

Parts involved: Fuel injector.

Ask the seller

“Has any injector been removed or resealed?”
“Any ticking or tapping noise from the top of the engine?”
“What injector service history is available?”

Other Ford Fusion engines and years6 documented issues that do not apply to the one you picked.

Engine, transmission & cooling3

012.0 EcoBoost Timing Chain Tensioner Wear

petrol2013–2019EngineDoes not apply$2,200–$5,500

OccasionalEngine $2,200–$5,500 to fix

Does not apply

The 2.0L EcoBoost (EcoBoost 2.0T) fitted to the Mondeo Mk5 uses a hydraulic timing chain tensioner that relies on adequate oil pressure and viscosity to maintain chain tension. The primary chain and its tensioner exhibit wear from cold-start oil starvation caused by delayed pressure build-up in the tensioner circuit. Over time the tensioner loses its ability to take up slack, allowing the chain to slap against the plastic guide rails. If left unaddressed the guides fracture, chain tension is lost entirely, and catastrophic valve-to-piston contact can occur. The failure rate is substantially higher in vehicles operated on extended oil change intervals or with oil consumption issues.

Symptoms to notice

Metallic rattling noise from front of engine on cold start lasting 5–20 seconds
Rattle diminishes or disappears once oil pressure builds at operating temperature
Engine management warning light with variable valve timing fault codes
Rough idle or hesitation linked to timing chain stretch fault P0016/P0017
Ticking or whirring from valve cover area at idle

What to check

Cold-start the engine immediately and listen from the passenger side of the engine bay for a metallic rattle lasting more than 3 seconds before fading.
Scan for stored codes P0016, P0017, P0022.
Review oil service history — chains fail faster on engines run past 10,000 km oil intervals.
Inspect valve cover area for oil leaks suggesting gasket degradation that coincides with chain wear.

Where to look: Front of engine, primary timing chain, tensioner on driver's side of block, upper and lower guide rails

Parts involved: Timing chain.

Ask the seller

“Has the timing chain or tensioner ever been inspected or replaced?”
“Has the vehicle been serviced strictly within Ford recommended oil change intervals?”
“Has there ever been a rattle on cold start that disappeared after warm-up?”
“Has the oil level ever dropped between services indicating consumption?”

02EcoBoost 1.5T timing chain tensioner rattle on cold start

Cold-start the engine after it has been sitting overnight and listen immediately for chain rattle from the front of the engine.petrol2014–2022EngineDoes not apply$1,500–$3,000

CommonEngine $1,500–$3,000 to fix

Does not apply

The 1.5-litre EcoBoost engine in the Mk5 Mondeo is fitted with a timing chain that develops rattle from a weak hydraulic tensioner, particularly on cold starts or when oil changes are overdue. Documented from approximately 60,000 km onward, the tensioner can lose pressure overnight and cause a pronounced rattle for up to 30 seconds after a cold start. Extended neglect risks chain jump and valve damage on this interference engine.

Symptoms to notice

Loud rattling from the front of the engine on cold start, lasting 10–30 seconds
Engine management light with timing/cam-crank correlation codes
Rough running immediately after a cold start
Rattle worsens after periods of non-use

What to check

Cold-start the engine after it has been sitting overnight and listen immediately for chain rattle from the front of the engine.
Scan for fault codes P0016 or P0017.
Review oil service history — late oil changes accelerate tensioner failure.

Where to look: Front of engine, behind the timing cover

Parts involved: Timing chain.

Ask the seller

“Has the timing chain tensioner been inspected or replaced?”
“Do you notice a rattling sound for the first few seconds after a cold start?”
“What oil grade is used and how often is it changed?”

032.0 TDCi diesel particulate filter blockage

Scan for DPF soot load percentage using a Ford IDS-compatible scanner.diesel2014–2022EngineDoes not apply$400–$2,800

CommonEngine $400–$2,800 to fix

Does not apply

Mk5 Mondeo TDCi models require sustained motorway driving to passively regenerate the diesel particulate filter (DPF). The short-trip urban usage typical in NZ and AU cities prevents adequate regeneration, leading to progressive blockage. Symptoms escalate from a dashboard warning to forced limp mode. A forced regeneration clears the fault temporarily but does not resolve the underlying usage pattern issue. Repeated failed regenerations also cause diesel contamination of the engine oil.

Symptoms to notice

DPF warning light on the instrument cluster
Reduced power and limp mode activation
Excessive black smoke on acceleration after warning light illuminates
Unexplained increase in engine oil level from diesel dilution during failed regeneration

What to check

Scan for DPF soot load percentage using a Ford IDS-compatible scanner.
Check oil level — a rising level indicates diesel contamination.
Ask about typical usage pattern and whether the car is used for mostly short urban trips.

Where to look: Exhaust system, behind the catalytic converter under the vehicle

Parts involved: Diesel particulate filter.

Ask the seller

“Has the DPF warning light ever illuminated?”
“Is this vehicle used mainly for short city trips?”
“Has a forced DPF regeneration ever been performed?”

Electrical1

012.0 Hybrid HV Battery Module Capacity Failure

Request a hybrid battery state-of-health report from a Ford dealer — IDS can display individual module voltages.hybrid2014–2019ElectricalDoes not apply$3,500–$9,000

OccasionalElectrical $3,500–$9,000 to fix

Does not apply

The Mondeo/Fusion Hybrid uses a 1.4 kWh nickel-metal hydride (NiMH) high-voltage battery pack mounted beneath the rear seat. Individual cell modules within the pack degrade unevenly; when one module reaches a state-of-health threshold below approximately 70% the battery management system restricts the usable capacity of the entire pack to prevent thermal imbalance. This manifests as a dramatic reduction in EV assist range and regenerative braking effectiveness. In advanced cases a cell group fails completely, triggering the orange triangle warning and reducing the vehicle to a limp-home charge-sustain mode with markedly higher fuel consumption. The failure is accelerated by exposure to sustained high ambient temperatures and vehicles that sat unused for extended periods allowing deep self-discharge.

Symptoms to notice

Fuel consumption significantly higher than Ford specification
Orange triangle or wrench warning light on dash
EV gauge shows minimal or no battery charge even after highway driving
Engine runs constantly with no EV assist at low speeds
Reduced or absent regenerative braking feel when lifting throttle

What to check

Request a hybrid battery state-of-health report from a Ford dealer — IDS can display individual module voltages.
Note fuel consumption from service records; degraded packs show 15–25% higher real-world fuel use.
Inspect rear seat base for evidence of prior battery access or replacement.
If a workshop inspection is possible: Scan high-voltage system with Ford IDS or compatible OBD tool for HV battery DTC codes B1318, U3000, or P0A80.

Where to look: High-voltage NiMH battery pack under rear seat squab, power control module in boot area

Ask the seller

“Has the hybrid battery ever been tested for state of health at a Ford dealer?”
“Has fuel consumption increased noticeably over the life of the vehicle?”
“Has the orange triangle or hybrid system warning ever illuminated?”
“Has the vehicle ever been left unused for more than 4–6 weeks?”

Body, brakes, suspension & interior2

01Panoramic Sunroof Drain Blockage — Water Ingress

Press carpet under all four footwell mats and check for moisture.2014–2019Body & RustDoes not apply$500–$4,000

CommonBody & Rust $500–$4,000 to fix

Does not apply

The Mondeo Mk5 fitted with the full-length panoramic roof shares the same narrow-bore corner drain architecture as the Kuga. Drains route from sunroof channels through A and C pillars, and blockage by debris causes water to overflow into the headliner and pillar cavities. In the Mondeo the drain failure is particularly consequential because water reaches the front and rear footwell BCM modules, the SYNC 3 infotainment ECU located beneath the central console, and in some cases the transmission control module mounted in the engine bay but with wiring looms passing through the A-pillar cavity. Electrical gremlins including infotainment resets, gear selector faults, and false ABS warnings are linked to this ingress pattern.

Symptoms to notice

Wet front or rear footwell carpet after rain
SYNC infotainment spontaneous reboots or blank screen
Musty odour from climate system vents
Staining along headliner edges or sail panel area
Intermittent ABS, transmission, or airbag warning lights

What to check

Press carpet under all four footwell mats and check for moisture.
Inspect C-pillar trim bases for tide marks.
Test sunroof drain flow by pouring water into each corner channel with sunroof open and confirm drainage exits under car within seconds.
Pull back front carpet edges to check for mould or rust on floor pan.
Inspect SYNC module under centre console for corrosion.

Where to look: Panoramic roof corner drains, A and C pillar cavities, front and rear footwells, SYNC module under centre stack

Ask the seller

“Has the panoramic roof drain system been serviced or flushed?”
“Has there been any damp smell or wet carpet?”
“Have there been electrical faults with the infotainment or warning lights?”
“Has any interior trim, carpet, or electrical module been replaced?”

02Rear Wheel Bearing Premature Failure

Rotate wheels by hand listening for roughness.2013–2019SuspensionDoes not apply$500–$1,200

CommonSuspension $500–$1,200 to fix

Does not apply

The Mondeo Mk5 rear suspension uses a multi-link arrangement with a sealed hub bearing unit that is notably susceptible to premature wear on New Zealand and Australian roads. The bearing is a two-row angular contact design that handles both radial load from vehicle weight and axial load during cornering; the sealing effectiveness degrades in environments with high humidity and road salt, allowing moisture and fine abrasive particles to enter the bearing races. On FWD models the bearings still carry substantial cornering loads via the independent rear geometry. Failure follows a progressive pattern from faint hum to loud drone, followed by ABS sensor errors as bearing play introduces runout into the tone ring, with eventual risk of brake pulsation and wheel separation in severe neglect cases.

Symptoms to notice

Cyclic droning or humming from rear escalating with vehicle speed above 70 km/h
Noise varies when gentle lateral weight transfer applied in motorway lane change
ABS or DSC warning light after bearing develops excessive runout
Vibration through rear seat at highway speed
Roughness felt when spinning rear wheel by hand on hoist

What to check

Rotate wheels by hand listening for roughness.
Test drive on smooth motorway surface and note any drone altering with gentle weaving.
Scan ABS module for wheel speed sensor codes that indicate bearing runout.
If a workshop inspection is possible: On a hoist grasp each rear wheel at 12 and 6 o'clock and at 3 and 9 o'clock positions and attempt to detect play in both planes.

Where to look: Rear hub bearing assemblies, pressed into multi-link rear knuckle, both sides

Parts involved: Wheel bearing.

Ask the seller

“Has either rear wheel bearing been replaced?”
“Is there any droning noise at highway speed?”
“Have ABS or stability control lights ever appeared without an obvious cause?”
“Has the vehicle been used near coastal areas where road salt is common?”

What these repairs cost on other cars

Some of the Ford Fusion’s documented faults are repairs other models share. Each page lists the documented NZ cost for every model it affects.

Other Ford models

Ford Ranger45 documented faults Ford Focus37 documented faults Ford Falcon36 documented faults Ford Courier10 documented faults Ford Transit10 documented faults Ford F-1509 documented faults

Ford Fusion buyer questions

Is the Ford Fusion reliable?

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?

We've catalogued 11 known faults for the Ford Fusion, covering engine, electrical, and body & rust. All 11 are written out in full on this page, with the symptoms to notice, what to inspect, and typical repair costs for each. Free to read, no account needed.

How much do repairs cost on a Ford Fusion?

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?

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 $24.90 far less than the cost of missing one of the faults on this page.