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Ford Fusion (Americas)

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Title: Ford Fusion (Americas)  
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Subject: Ford Taurus (fourth generation), Flat Rock Assembly Plant, Ford Taurus (fifth generation), Ford EcoBoost engine, Ford Focus (third generation)
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Ford Fusion (Americas)

Ford Fusion
Manufacturer Ford Motor Company
Production August 2005–present[1]
Assembly Flat Rock, Michigan, USA (Flat Rock Assembly Plant)
Hermosillo, Sonora, Mexico (Hermosillo Stamping & Assembly)
Body and chassis
Class Mid-size
Body style 4-door sedan
Predecessor Ford Contour
Ford Taurus (fourth generation)

The Ford Fusion, code named CD338 for the first generation (2005–12), is a mid-size car produced by the Ford Motor Company since the 2006 model year. The 2010 model was awarded the Motor Trend Car of the Year[2] and its hybrid version won the 2010 North American Car of the Year Award.[3] The Fusion is manufactured at Ford's Hermosillo Stamping & Assembly where the similar (and now discontinued) Mercury Milan and the Lincoln MKZ were also built.[4] All three cars utilize the CD3 platform.

Production on the first Fusions began on August 1, 2005.[1] The Fusion replaced the Mondeo for the Latin American markets—except in Argentina (where the current European Mondeo is available) and in the United States and Canada (where it superseded the then mid-size Taurus). The Fusion is positioned between the compact Ford Focus and full-size Ford Taurus.[5] In the Middle East, this model is sold alongside the Mondeo. Versions sold there are available only with the 2.5-litre engine. Unlike in the United States, Canada and Latin America, no V6 engine is available in that region.[6] The same is true in South Korea, where only the 2.5-liter engines (including those for the hybrid model) are available as of the 2012 model year.

The Fusion was the first production car to feature the "new face of Ford" three-bar grille, which (along with two matching bars below the bumper/fascia forming a five-bar design) was first seen on a retro V10-powered rear-wheel-drive concept car called the Ford 427, unveiled in 2003 at the North American International Auto Show (NAIAS) in Detroit. The look has since been used on most of Ford's product line.

The second generation line-up includes a gasoline engine option, an EcoBoost engine option, a next-generation hybrid model, and a plug-in hybrid version, the Ford Fusion Energi, making the Ford Fusion the first production sedan to offer these four options. Sales of the gasoline-powered and hybrid versions began in the U.S. in October 2012 under the 2013 model. Sales in Europe and Asia, as Ford Mondeo, are expected to begin in 2015, along with South Africa, where the Fusion name will be used.[7] Deliveries of the Fusion Energi began in the U.S. in February 2013. The entire 2013 Ford Fusion line-up was awarded with the 2013 Green Car of the Year at the 2012 Los Angeles Auto Show.

First generation (2005–2013)

First generation
Production August 2005—February 2, 2009 (initial run)
Model years 2006–2009
Designer Chris Walter (2002)[8][9]
Body and chassis
Platform Ford CD3 platform
Engine 2.3 L Duratec 23 I4
3.0 L Duratec 30 V6
Transmission 5-speed Mazda G5M manual (I4)
5-speed Mazda FNR5 automatic (I4)
6-speed Aisin TF-80 automatic
Wheelbase 107.4 in (2,728 mm)
Length 190.2 in (4,831 mm)
Width 72.2 in (1,834 mm)[10]
Height 57.2 in (1,453 mm)
Curb weight 3,280 lbs.[10]

At its launch, the Fusion was available in S, SE, and SEL trims. The base engine was the 160 hp (119 kW) Mazda-designed 2.3 L Duratec 23 I4, paired with either a 5-speed manual or 5-speed automatic transmission. SE and SEL models were available with a 221 hp (165 kW) 3.0 L Duratec 30 V6 and a 6-speed automatic.[10]

The Fusion shares some interior parts with the otherwise unrelated Mk III Ford Mondeo, such as part of the console and the seats. Both automatic and manual transmissions are available (the latter only with the I4 engine).

Ford's early advertising campaign for the Fusion in the United States was entitled "Life in Drive", while in Canada it was "Create a Reaction".[11] In January 2007, the company launched a new campaign for the Fusion titled "Fusion Challenge" (later renamed "Ford Challenge"). The American Ford Fusion emerged the winner over the Toyota Camry and Honda Accord based on the attributes of styling, handling, and “fun to drive” in head-to-head comparison tests with the Japanese sedans performed by subscribers of Car and Driver and Road and Track magazines in the Washington D.C. and Los Angeles regions.

For 2007, all-wheel-drive became available on V6 models. Sirius Satellite Radio is available as an option on the SE and SEL models. The front passenger fold-flat seat was introduced and became standard on the Fusion SEL and SE models. Also, the Fusion now has front-seat side airbags and a side air curtain as standard features, as well as an anti-theft perimeter alarm. (All were previously available as cost options.) Also added is an auxiliary audio input jack for audio transmission from a portable audio player along with some equipment modifications. A DVD-based navigation system also became available.

For the 2008 model year, ABS became a standard feature, as did a tire pressure monitoring system. New optional features include rear parking assist, Ford's "SYNC" multimedia and communication system, and ambient interior lighting. The DVD navigation was replaced with a new generation system featuring voice commands, and for the first time navigation is available also with manual transmission. Finally, 2 packages were added to the options list: Sport Appearance Package and Moon and Tune package. The latter makes the Audiophile 8-speaker audio system available on the SE trim line. Several colors were deleted and some others added.

For 2009, electronic stability control was added as an option. A new appearance package with blue trim became available, and revisions were made to the exterior color palette as well.

In Mexico the Fusion was offered in two trim levels through 2005-06: SE and SEL, with automatic transmission only. For the 2007 model year, the S trim was introduced and a manual transmission was newly available for the S and SE trim levels. These two trims had standard 16-inch alloy wheels, while the SEL trim had 17-inch alloy wheels standard. The 2008 model year added Ford's Ford SYNC to the SEL trim. The manual transmission was discontinued after 2008 in Mexico due to poor sales. The 2009 model year was a very short one in Mexico because the 2010 Fusion arrived in dealerships by late February 2009.

The equipment on all of the Fusion models is as follows:

For 2006-2009:

The S was the base model, including the 2.3L Duratec I4 engine, automatic transmission, A/M-F/M stereo with single-disc CD player and four speakers plus an auxiliary audio input jack, sixteen-inch steel wheels with plastic wheel covers, cloth seating surfaces, and keyless entry.

The SE was the step-up model, adding seventeen-inch alloy wheels, A/M-F/M stereo with single-disc CD/MP3 player, power front driver's seat, and a security system.

The SEL was the top-of-the-line model, adding power dual front seats and later offering a standard Ford SYNC system.

For 2010-2012:

The S was once again the base model, including the 2.5L Duratec I4 engine, automatic transmission, A/M-F/M stereo with single-disc CD/MP3 player, auxiliary input jack and four speakers, sixteen-inch wheels, cloth seating surfaces, and keyless entry.

The SE was the mid-range model, adding seventeen-inch alloy wheels, six speakers, and power front driver's seat, as well as a security system. SIRIUS Satellite Radio also came standard on this model.

The SEL was the upper-end model, adding standard Ford SYNC system, later standard leather seating surfaces, and dual power front seats.

The Sport was the sports model, adding standard eighteen-inch alloy wheels, darkened front grille and rear bow lip, rear spoiler, leather seating surfaces with suede inserts, heated front seats, a Sony premium 292-watt sound system with subwoofer and external amplifier, a 3.5L Duratec V6 engine, and a sunroof.

The Hybrid model added onto the SEL model, with a 2.5L Duratec I4 engine assisted by an Atkinson hybrid electric motor, an electroluminescent Optitron-style gauge cluster, dual power front seats, and an Eco Driving mode to tell the driver how economically s/he is driving.


Engine Displacement Power Torque
2.3 L Duratec 23 138 CID 160 hp (119 kW) 156 lb·ft (212 N·m)
3.0 L Duratec 30 V6 182 CID 221 hp (165 kW) 205 lb·ft (278 N·m)

Crash testing

National Highway Traffic Safety Administration:

  • Frontal Driver (2006, 07, 08 early release):[12][13][14] 4/5 stars
  • Frontal Driver (2008 later release, 09–present):[15][16] 5/5 stars
  • Frontal Passenger (2006, 07, 08 early release):[12][13][14] 4/5 stars
  • Frontal Passenger (2008 later release, 09–present):[15][16] 5/5 stars
  • Side Driver (no side airbag, 2006 only):[12] 4/5 stars
  • Side Driver (side airbag): 5/5 stars
  • Side Rear Passenger (no side airbag, 2006 only):[12] 4/5 stars
  • Side Rear Passenger (side airbag): 4/5 stars
  • Rollover FWD: 4/5 stars
  • Rollover AWD: 5/5 stars

Insurance Institute for Highway Safety:

  • Frontal Offset (2006, 07 early release):[17] Acceptable
  • Frontal Offset (2007 later release, 08–present):[18] Good
  • Side Impact (no side airbag, 2006 only):[19] Poor
  • Side Impact (side airbag 2006, 07 early release):[20] Acceptable
  • Side Impact (2007 later release, 08–present):[21] Good
  • Roof Strength (2005–10 mfg before May 2010):[22] Acceptable
  • Roof Strength (2010 mfg after April 2010–present): Good

Although the frontal offset test for 2007 (later release) to present model is rated good overall by IIHS, injury measures from head/neck and right leg/foot is rated acceptable.[17]

2010 revision

Production February 5, 2009—2012[23]
Model years 2010–2012
Designer Chris Walter (2007)
Body and chassis
Platform Ford CD3 platform
Engine 2.5 L Duratec 25 I4
3.0 L Duratec 30 V6
3.5 L Duratec 35 V6
Transmission 6-speed Mazda G6M manual (I4)
6-speed Ford 6F35 automatic (I4 & 3.0L V6)
6-speed Aisin TF-80 automatic (3.5L V6)
Continuous variable transmission (hybrid)
Wheelbase 107.4 in (2,728 mm)
Length 190.6 in (4,841 mm)
Width 72.2 in (1,834 mm)
Height 56.9 in (1,445 mm)
2010–2012 Ford Fusion S

For the 2010 model year, Ford significantly updated the Fusion,[24] along with the Mercury Milan and Lincoln MKZ,[25] with new front and rear end fascia designs[26][27] and interior and powertrain revisions. Powertrain options are similar to those that debuted on the 2009 Ford Escape, including the new 2.5 L I4 and 3.0 L PIP Duratec series V6 engine coupled to Ford's new 6F35 six-speed transmission.[28] The 3.0 L Duratec now provides 240 hp (179 kW) with E85 fuel capability, while the I4 provides 175 hp (130 kW). The 3.5 L Duratec 35 producing 263 hp (196 kW) is standard in the Fusion Sport. The I4 and 3.0 L V6 engines include adaptive knock control and aggressive deceleration fuel cutoff features to improve fuel economy.[29] Interior redesigns include a new optional 8" screen navigation control system, a new center console design, and Ford's new trademark "Ice Blue" illumination for the controls and gauges that is shared with the current Ford Focus and Ford F-150.

In July 2007, Motor Trend reported that Ford's Special Vehicle Team tuner group planned to release a Fusion GT in late 2009 or early 2010. Its 3.5-liter Eco-Boost V-6 would make about 340 horsepower.[30] No such vehicle ever came to fruition.

The refreshed version comes in 4 trim levels: S, SE, SEL and Sport. In Mexico, the S trim now comes standard with 16-inch steel wheels with full wheel covers, unlike the American and Canadian models that come with 16-inch alloy wheels. The SYNC system is not available in this trim. The SE trim now has two engine choices. A 4-cylinder and a V6 are available, and come standard with 17-inch steel wheels with full wheel covers, fog lights, and colored keyed mirrors. A sunroof is also an available option in the SE trim. The SEL trim comes standard with 17-inch alloy wheels, the SYNC system, and is also available in 4- and 6-cylinder engines. Leather upholstery is standard. A sunroof is also available in the SEL trim. The Sport trim adds spoilers, side skirts and comes standard with 18-inch alloy wheels.

Hybrid electric version

The Fusion Hybrid has digital panels to track eco driving (top), and current hybrid drive propulsion (bottom).

The 2010 Ford Fusion Hybrid is a gasoline-electric hybrid powered version of the mid-size Fusion sedan launched to the U.S. market in March 2009, with an initial sale price of US$27,270.[31] EPA ratings for the Ford Fusion Hybrid are 41 mpg city and 36 mpg highway. In city driving a full tank delivers 700 miles.[32] In April 2009 editors of Kelley Blue Book named the 2010 Ford Fusion Hybrid to its 2009 list of "Top 10 Green Cars".[33]

The Fusion Hybrid qualified for a hybrid tax credit of US$3,400 prior to March 31, 2009. The credit dropped to US$ 1,700 if purchased by September 30, 2009, and to US$850 if purchased by March 31, 2010. This credit phased out on April 1, 2010.[34]

This model gets better EPA-estimated fuel economy than the Toyota Camry Hybrid, the Nissan Altima Hybrid, and the Chevrolet Malibu Hybrid, viewed as its competitors in the mid-size sedan segment.


Engine Displacement Power Torque Gas Mileage 0-60 Times
2.5 L Duratec 25 I4 152 CID 175 hp (130 kW) 172 lb·ft (233 N·m)[35] 23 mpg city/33 mpg highway/26 mpg combined (automatic); 22/30/25 (selectshift, SE/SEL trims); 22/32/25 (manual, S trim); 22/29/24 (manual, SE trim)[36] 8.0 sec
3.0 L Duratec 30 V6 182 CID 240 hp (179 kW) 223 lb·ft (302 N·m) 20/28/23 FWD; 18/26/20 AWD, gasoline/E85 flex fuel 7.4 sec
3.5 L Duratec 35 V6 213 CID 263 hp (196 kW) 249 lb·ft (338 N·m) (Fusion Sport); 18/27/21 FWD; 17/24/19 AWD 6.5 sec
2.5 L Duratec 25 I4 152 CID 156 hp (116 kW); 191 hp (142 kW) combined 136 lb·ft (184 N·m)[37] (Hybrid) 41/36/39 7.8 sec

Safety ratings

The Ford Fusion line-up was included in the Insurance Institute for Highway Safety 2010 "Top Safety Picks" rating for the mid-size category.[38][39] Due to the fact that Ford recently modified and strengthened the roof structure of the Flex, Fusion, and MKT vehicles, these 2010 ratings apply only to Lincoln MKZs, Mercury Milan and Fusions built after April 2010.[38]

Safety concerns

In June 2010, it is reported that National Highway Traffic Safety Administration was investigating into floormat-related unintended acceleration in 2010 Ford Fusion and Mercury Milan. According to NHTSA's estimate, as many as 249,301 cars could be affected.[40]

On May 28, 2010, the NHTSA issued a statement that the stacking of all-weather floor mats from any manufacturer on top of the factory floor mat could cause accelerator entrapment. In their press release they stated the following: "NHTSA is urging drivers of 2010 Fusions to make sure they do not stack the rubber “All Weather” floor mat on top of the secured carpeted floor mat. Further, drivers are reminded to ensure that any driver-side floor mats (whether they are the carpeted floor mat or all weather floor mat) are properly installed and restrained by the retention hooks on the floorboard. Depending on vehicle and floor mat design, it is possible for unsecured floor mats to interfere with accelerator or brake pedals in a wide range of vehicles. Therefore, NHTSA reminds all drivers of all makes and models to check the driver-side floor mats for secure installation and to follow all manufacturer instructions for installing the mats."[41]

Second generation (2013–)

Second generation
Also called Ford Mondeo (Europe)
Production Hermosillo, Sonora, Mexico (Hermosillo Stamping & Assembly)
Flat Rock, Michigan, U.S. (Flat Rock Assembly Plant)
Designer Chris Hamilton, Kemal Curic (2010)[42][43][44]
Body and chassis
Platform Ford CD4 platform
Related Ford Mondeo
Ford Fusion Energi
Lincoln MKZ
Ford C-Max Hybrid
Engine 1.5 L EcoBoost I4
1.6 L EcoBoost I4
2.0 L EcoBoost I4
2.5 L Duratec I4
Transmission 6-speed Ford B6 manual (1.6 EcoBoost only)
6-speed Ford 6F automatic (all engines)
CVT, Ford HF35 (hybrid and PHEV)
Wheelbase 112.2 in (2,850 mm)
Length 191.7 in (4,869 mm)
Width 72.9 in (1,852 mm)
Height 58.1 in (1,476 mm)
Curb weight 3,323–3,427 lb (1,507–1,554 kg)

The all-new model year 2013 Ford Fusion is the next step on the Ford Global-Car strategy, started with the Focus and then the extension of Fiesta production into North America, both in 2012. Like the previous generation Fusion, the final assembly takes place at Hermosillo Stamping & Assembly, Hermosillo, Sonora, Mexico. Due to strong sales of the redesigned 2013 year model, additional capacity was added in Flat Rock Assembly Plant, Michigan. This is the second time (Ford manufactured the Fusion at Flat Rock since 2005) the Fusion is built in the U.S. and assembling at Flat Rock began in August 2013. The hybrid version and the Fusion Energi plug-in hybrid will continue to be produced exclusively in Mexico.[45]

Lead designer [47]

The Fusion was unveiled at the 2012 North American International Auto Show. The new car has a 122 mm (4.8 in) bigger wheelbase, is 28 mm (1.1 in) longer 18 mm (0.7 in) wider and 31 mm (1.2 in) taller than the outgoing model, based on the Mazda-derived CD3 platform. The car will be built on the new CD4 platform that is reportedly 10 percent stronger than both the outgoing Fusion's CD3 platform and the Mondeo's EUCD platform. In contrast to the front double wishbone suspension of the first generation Fusion, at front are MacPherson struts, and at rear is an all-new multi-link rear suspension. Ford claims the car has been conceived as a driver’s car. Despite larger exterior dimensions, some aspects of the interior have shrunk, including the trunk, which has fallen from 467 to 453 L (16.5 to 16.0 cu ft).

2013 model year Ford Fusion line-up, unveiled at the 2012 North American International Auto Show

The 2013 Fusion is available in S, SE, and Titanium trim levels. In an effort to offer its customers a "Power of Choice," Ford has assembled five different powertrains for the new model, including two hybrid variants. All available engines are now four-cylinder offerings, dropping the previous model's 3.0L V6 as the top tier engine choice, as part of Ford's push to phase out the aging Duratec 30, as well as the Sport package's 3.5L V6 as a performance option. Engine options available at launch are identical to those of the redesigned Escape CUV:

  • Duratec 2.5 I4- offered as the standard engine, producing 175 bhp (130 kW; 177 PS) and 175 lb·ft (237 N·m). of torque. The engine will be mated to a FWD 6F automatic transaxle.
  • EcoBoost 1.6L I4- aimed towards customers who want a power and fuel efficiency boost over the base engine, without paying the "hybrid premium." Output is at 182 bhp (136 kW; 185 PS) and 184 lb·ft (249 N·m) of torque, a small increase from the base engine. However, highway fuel economy is estimated at 37 mpg, making it best-in-class for non-hybrid midsize sedans. Transmission choices for the Ecoboost 1.6L are the B6 6-speed manual and the 6F automatic. An auto start-stop system is offered for the 1.6-liter EcoBoost engine paired with the automatic transmission, at a price of US$295.[48] 2014 Fusions with the 1.6L EcoBoost engine are paired exclusively to the 6-speed manual transmission.
  • EcoBoost 1.5L I4 - for model year 2014, this engine replaces the EcoBoost 1.6L I4 unit on Fusion models equipped with the automatic transmission. Output is comparable to the 1.6L, at 178 bhp (133 kW; 180 PS) and 177 lb·ft (240 N·m) of torque. Notable design features of the 1.5L EcoBoost engine include an exhaust manifold integrated with the cylinder head and a liquid cooled charge air cooler.[49]
  • EcoBoost 2.0L I4- This engine replaces the now obsolete Duratec 30 V6, producing similar power, more torque, and better fuel economy. Output is the same as the Escape at 240 bhp (179 kW; 243 PS) and 270 lb·ft (370 N·m). of torque through a 6F35 transmission with SelectShift capability. Steering-wheel mounted paddle shifters will are offered on the Titanium trim, while a sequential shift lever is on S and SE trims. AWD is an exclusive option to this engine choice.
  • Duratec 20 I4 (Hybrid)- Out goes the previous 2.5L hybrid engine in favor of the smaller and more efficient Duratec 20. The 2.0L engine is modified to run in an Atkinson Cycle fashion, coupled to an electric motor through a new Ford designed and manufactured HF35 CVT. This powertrain is available as a standard hybrid, or as a plug-in model, dubbed the Fusion Energi.

In Europe and the rest of the world the launch is scheduled for the third quarter of 2013, the engine range will be similar, but the 2.5 will only be available in North America. In the rest of the world, there will be added a three-cylinder 1.0L 123 bhp EcoBoost, claimed to produce just 125g/km of CO2 emissions; and the Ford Fusion Energi plug-in hybrid is expected to be released between 2014 and 2015.[46]

The 2013 Fusion includes driver assistance and technologies based on sensors, cameras and radar that enable the car to see and respond. Fusion can help drivers maintain proper lane position (Lane Keeping System); adjust vehicle speed to changing traffic conditions through adaptive cruise control; active park assist to help identify suitable parking spaces and help park; and Blind Spot Information System (BLIS) with cross-traffic alert, which consists of sensors in both rear quarter-panels that are able to detect traffic in a driver’s blind spot, providing both audible and visual warnings if traffic unseen by the driver is detected. BLIS technology enables cross-traffic alert, even aiding drivers backing out of parking space where visibility is obstructed.[50][51]

The new 2013 line-up also includes a next-generation hybrid version, and a plug-in hybrid version, the Ford Fusion Energi. The Ford Fusion became the first production sedan to offer these three options.[52] Sales of the gasoline-powered and hybrid version began in the US in October 2012.[53] Sales in Europe and Asia, as Ford Mondeo, are expected to begin in 2013.[54] Deliveries of the Fusion Energi began the U.S. in February 2013.[55][56] Sales of the Mondeo line-up, including the hybrid model, began in Germany in August 2014.[57]

For the second generation Fusion Hybrid the nickel-metal hydride batteries used in the hybrid first generation were replaced with lithium-ion batteries.[54] The 2013 model year is more fuel efficient than its predecessor, with a US Environmental Protection Agency (EPA) rating of 47 mpg-US (5.0 L/100 km; 56 mpg-imp) with the same rating for combined/city/highway cycles. This rating is also the same Ford achieved for the 2013 Ford C-Max Hybrid, as both hybrids share the same engine and drivetrain. These ratings allowed the 2013 Fusion Hybrid to outperform the 2012 Toyota Camry Hybrid LE by 4 mpg-US (59 L/100 km; 4.8 mpg-imp) city and8 mpg-US (29 L/100 km; 9.6 mpg-imp) highway, and to become the most efficient midsize hybrid sedan in the U.S. as of September 2012.[58] The Duratec 2.5, and EcoBoost 1.5, 1.6 and 2.0 are sourced from Chihuahua, Mexico, Craiova, Romania, Bridgend, Wales, and Valencia, Spain, respectively. The 6F and HF35 automatic transmissions are sourced from Ford's Van Dyke Transmission Plant in Sterling Heights, Michigan, while the B6 manual is produced at the GETRAG FORD Transmissions GmbH facility in Halewood, United Kingdom.

The models were:

The S was the base model, offering a 2.5L Duratec I4 engine, manual or automatic tranmission, an A/M-F/M color screen stereo with single-disc CD/MP3 player, and USB and auxiliary input jacks and SIRIUS Satellite Radio, the Ford SYNC System, four speakers, cloth seating surfaces, sixteen-inch steel wheels with plastic wheel covers, and keyless entry with a switchblade-style key.

The SE added six speakers, seventeen-inch alloy wheels, and a power front driver's seat.

The Titanium (replacing the SEL) added leather seating surfaces, heated front seats, dual power front seats, the MyFord Touch System with an A/M-F/M HD Radio radio, a single-disc CD/MP3 player, SD card slot, USB, A/V, and auxiliary input jacks, push-button start, keyless access, a Sony 390-watt premium surround-sound system, and eighteen-inch alloy wheels.

The Hybrid model for 2013 was separated into three trims: the S, the SE, and the Titanium, as well as offering a plug-in hybrid model on the SE and Titanium trims. All hybrids included alloy wheels and a fully digital gauge cluster, as well as offering all the standard features of the standard Fusion trims.


Engine Displacement Power Torque Gas Mileage/Transmission
2.5 L Duratec 25 I4 152 CID 175 hp (130 kW) 170 lb·ft (230 N·m) 22/34/26 (6F 6-Speed Automatic)
1.5 L EcoBoost Turbocharged I4 92 CID 178 hp (133 kW) 177 lb·ft (240 N·m) N/A (6F 6-Speed Automatic)
1.6 L EcoBoost Turbocharged I4 97 CID 178 hp (133 kW) 184 lb·ft (249 N·m) 25/37/29 (6-speed Ford B6 manual)
2.0 L EcoBoost Turbocharged I4 122 CID 240 hp (179 kW) 270 lb·ft (366 N·m) 22/33/26 (FWD); 22/31/25 (AWD) (6F 6-Speed Automatic)
2.0 L Duratec 20 I4 122 CID 141 hp (105 kW), 188 hp (140 kW) peak horsepower 129 lb·ft (175 N·m); 177 lb·ft (240 N·m) peak torque 47/47/47 CVT, Ford HF35 (hybrid and PHEV)


  • 1. The Ford Fusion was recalled in December 2012 for engine fires, along with the Ford Escape, which shares its 1.6L EcoBoost four-cylinder engine.[59] The number of vehicles affected by this recall are estimated at 89,000 (including the Escape).
  • 2. There has also been a recall for the low beam headlamp projectors, whose coating may have been improperly applied during the manufacturing process by the supplier, which could cause the lamp to become hazy which decreases driver visibility and increases risk of accidents. Approximately 19,000 vehicles have been affected by this second recall.[60]

As a result of these recalls some 30,000 vehicles were held at the Hermosillo Mexico manufacturing plant or shipped to Flat Rock, Michigan for repair prior to customer delivery. Some order placed in August 2012 hadn't arrived until around April 2013.[61]


In a 2012 comparison test by Motor Trend, the Ford Fusion came in third place out of six cars behind the first place Volkswagen Passat and second place Honda Accord.[62]

Consumer Reports in its December 6, 2012 publication found that the Ford Fusion Hybrid and Ford C-Max Hybrid's tested fuel economy was 20% (8 MPG) short of Ford's EPA mileage claims. After many reports from owners and media of the Ford Fusion Hybrid getting less than the stated 47 MPG city/47 MPG highway/47 MPG combined, a class action lawsuit was brought against Ford on December 26, 2012.[63][64] Consumer Reports reviewed several other vehicle makes and models and found the Fusion Hybrid from Ford were the worst under-performers compared to EPA fuel efficiency ratings in real world usage compared to 16 others including hybrids.[65]

For the 2014 model year the chief improvement is a new 1.5-liter four-cylinder engine option.[66]

Background on name choice

The Fusion was originally to be called the Futura, which was last used in North America as a name applied to the Fairmont model line ("Fairmont Futura"). Ford, however, lost a trademark lawsuit to the Pep Boys auto parts store, which has a line of tires under the Futura brand.[67] American trademark law generally considers a name abandoned if the owner does not use it for three calendar years and the long history of the name in the Ford line did not impress the court.

The Futura name was originally introduced as a Lincoln concept car in 1955. The Lincoln Futura later was converted to the Batmobile for the television series Batman (1966–1968).[68] In 1961, it was first used as the designation of an upper trim level on Falcons which continued through 1970, and then on a 2-door coupe and eventually also 4-door versions of the Ford Fairmont from 1978 to 1983. The name was also used by Ford Australia as a trim line for the Falcon until the release of BF (MY 2006). Pep Boys does not operate in Australia, thus there was no conflict of trademark in that country.



The 2013 NASCAR Sprint Cup Series Generation 6 version of the Ford Fusion as driven by Ricky Stenhouse, Jr. at Martinsville Speedway.

The Fusion also became the new body style for Ford automobiles in NASCAR beginning in 2006, replacing the Taurus.[69] This marked the first time since the Torino in 1968 that Ford introduced a new model that went racing in NASCAR at the same time as its launch. It debuted at the 2006 Daytona 500 and won its first race a week later in California when Matt Kenseth took the checkered flag. For safety reasons, the Car of tomorrow became the car style for the NASCAR Sprint Cup Series from the 2008 season,[70] but Ford continued to use the Fusion name. Kenseth took his #17 Fusion to victory lane in a rain-shortened Daytona 500 in 2009 and did so again (as a rain-delayed race) in 2012. On February 20, 2011, the #21 Motorcraft Ford Fusion driven by 20-year-old Trevor Bayne won the Daytona 500, echoing the NASCAR Hall of Fame Inductee, David Pearson, when he won it in a similarly decorated Mercury in 1976. The #21 car is owned by the legendary Wood Brothers. Nascar Drivers Aric Almirola, Blake Koch, Boris Said, Brad Keselowski, Carl Edwards, David Gilliland, David Ragan, Eddie McDonald, Greg Biffle, J.J. Yeley, Joey Gase, Joey Logano, Marcos Ambrose, Ricky Stenhouse Jr. Terry Labonte, Timmy Hill, Travis Kvapil, and Trevor Bayne drive Fusions.

Land speed record success

Ford announced its attempt to use a fuel cell version of the Fusion, Ford Fusion Hydrogen 999, to set a land speed record on August 10–17 during Bonneville Speed Week in 2007.[71] The Fusion 999 project was born in early 2006 when Ford fuel cell engineering manager Mujeeb Ijaz approached Roush Racing about a project to demonstrate the performance potential of a fuel cell-powered vehicle.

Roush's team, led by Rick Darling, worked with a team of Ford engineers and technicians led by Matt Zuehlk to come up with a vehicle design that could meet the goal of exceeding 200 mph (320 km/h) on the Bonneville Salt Flats, fueled only by hydrogen.[72] On August 15, 2007, the vehicle set the fastest fuel cell ground vehicle speed record of 207.297 mph (333.612 km/h).

The car was driven by retired Ford engineer Rick Byrnes, a long time Bonneville racer.[73]

Consumer response

According to Ford, consumer response to the 2006 Fusion had exceeded their expectations,[74] with 30,000 sold during the first quarter of 2006. By October 2009, the Fusion became one of the top ten best-selling cars in the U.S. for the first time, as well as the best-selling car by a domestic automaker.[75]

An article reflecting on the retirement of the Taurus however noted that whatever its faults, Ford did sell a large volume of them, and at the time production ended, the Taurus was still outselling the smaller Fusion and larger Ford Five Hundred combined, thanks to Taurus' large fleet sales. For the 2007 model year, approximately 77% of Fusion sales were retail (as opposed to fleet).[76] This sales mix has contributed, in part, to the Fusion's relatively high residual value compared to the Taurus.[77]

Ford also sells the Fusion in Mexico and Brazil. In Brazil, it became the highest-selling car in its class in 2008.[78]


2010 Motor Trend Car of the Year trophy won by the Ford Fusion line-up exhibited at the 2010 Washington Auto Show.
  • In July 2006, Strategic Vision gave the Fusion its Total Quality Award as the best-quality midsize sedan on the American market.[79]
  • In March 2006, the International Carwash Association named the Fusion America's "Most Washable Car."[80]
  • In December 2009, Car and Driver magazine listed the 2010 Fusion Hybrid as one of the "10 Best Cars". The piece stated that the Fusion Hybrid was the most advanced of all the cars they tested.[82]


  • Consumer Reports has also given positive reviews to the Fusion, as it had to the previous Taurus. It rated the Fusion Hybrid the top domestic sedan for 2010.[87] In 2009, the magazine's automotive editor, Rik Paul, said, "The Ford cars outscored Honda's Accord and Toyota's Camry, the two top-selling cars in America, 'which many people view as the paradigms of reliability'," referring to the Fusion and Mercury Milan.[88]
  • Ford Fusion ranked highest among midsize cars in the JD Power APEAL study for 2006.[89]

Yearly U.S. sales

2005[92] 16,983 n/a
2006[92] 142,502 +739%
2007[92] 149,552 +5.0%
2008[92] 147,569 −1.3%
2009[92][93] 180,671 +22.4% 15,554 8.6%
2010[92][94] 219,219 +21.3% 20,816 9.5%
2011[92][95] 248,067 +13.2% 11,286 4.5%
2012[96][97] 241,263 -2.7% 14,100 5.8%
2013[92][98] 295,280 +22.4% 37,270 12.6% 6,089 2.1%
Cumulative sales
1,641,106 n/a 99,026 6.0% 6,089 0.4%
Notes: YOY: year-over-year, n/a: not applicable


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External links

  • Official site
  • 2010 Ford Fusion Sport review at
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