2016 Ford Fusion

The 2016 Ford Fusion is a mid-size sedan known for its stylish design, comfortable ride, and available hybrid and plug-in hybrid powertrains. Common engine options include the 2.5L Duratec I4 (175 hp, 175 lb-ft torque), the 1.5L EcoBoost I4 (181 hp, 185 lb-ft torque), the 2.0L EcoBoost I4 (240 hp, 270 lb-ft torque), and a hybrid 2.0L Atkinson-cycle I4. Transmission options include a 6-speed automatic for the gasoline engines and an eCVT for the hybrid models. People generally appreciate the Fusion’s fuel efficiency, handling, and interior design. Some common dislikes include the MyFord Touch infotainment system (although it was upgraded to SYNC 3 for later models) and reported reliability issues.

Engine

2.5L Duratec I4

• No Known Common Issues
  • Description/Symptoms: No known prevalent issues
  • Solution: N/A
  • Estimated Cost to Fix: N/A
  • Recalls: None Found

1.5L EcoBoost I4

• Coolant Intrusion into Cylinders
  • Description/Symptoms: This issue arises from cylinder head design flaws, leading to coolant leaks into the combustion chamber. Symptoms include white smoke from the exhaust, rough running engine, coolant loss without external leaks, and potentially catastrophic engine failure.
  • Solution: Replacement of the engine is usually necessary
  • Estimated Cost to Fix: $4,000 - $7,000+
  • Recalls: None Found

2.0L EcoBoost I4

• Turbocharger Failure
  • Description/Symptoms: The turbocharger can fail due to oil starvation or general wear and tear. Symptoms include loss of power, excessive smoke, whistling noises from the engine bay, and the engine running in “limp mode”.
  • Solution: Replacement of the turbocharger. Inspect oil lines to ensure proper lubrication.
  • Estimated Cost to Fix: $1,500 - $3,000+
  • Recalls: None Found

Hybrid 2.0L Atkinson-cycle I4

• No Known Common Issues
  • Description/Symptoms: No known prevalent issues
  • Solution: N/A
  • Estimated Cost to Fix: N/A
  • Recalls: None Found

Transmission

6-Speed Automatic (Gasoline Engines)

• Harsh Shifting/Slipping
  • Description/Symptoms: Some owners report harsh or erratic shifting, slipping between gears, or delayed engagement.
  • Solution: In some cases, a transmission flush and software update may resolve the issue. In others, a valve body replacement or full transmission rebuild/replacement is necessary.
  • Estimated Cost to Fix: $150 (flush) - $4,000+ (rebuild/replacement)
  • Recalls: None Found

eCVT (Hybrid Models)

• No Known Common Issues
  • Description/Symptoms: No known prevalent issues
  • Solution: N/A
  • Estimated Cost to Fix: N/A
  • Recalls: None Found

Suspension

• Premature Wear of Suspension Components
  • Description/Symptoms: Owners have reported premature wear of suspension components, such as struts, shocks, and control arm bushings. This can lead to a bouncy ride, uneven tire wear, and clunking noises from the suspension.
  • Solution: Replacement of worn suspension components. A full alignment after repairs.
  • Estimated Cost to Fix: $200 - $1,000+ depending on the number of parts replaced
  • Recalls: None Found

Electrical

• SYNC System Issues
  • Description/Symptoms: Problems with the SYNC infotainment system, including freezing, slow response times, Bluetooth connectivity issues, and screen malfunctions. This is more prevalent with the MyFord Touch system but can also occur with SYNC 3.
  • Solution: Software updates, system resets, or replacement of the SYNC module.
  • Estimated Cost to Fix: $0 (software update) - $800+ (module replacement)
  • Recalls: None Found
• Battery Drain
  • Description/Symptoms: Excessive battery drain, leading to a dead battery, especially if the vehicle sits for extended periods. This can be caused by parasitic draw from various electrical components.
  • Solution: Diagnosis and repair of the source of the parasitic draw. This may involve replacing faulty modules or wiring repairs.
  • Estimated Cost to Fix: $100 - $500+
  • Recalls: None Found

Exterior

• Door Latch Issues
  • Description/Symptoms: Difficulty opening or closing doors, doors not latching properly.
  • Solution: Door latch replacement.
  • Estimated Cost to Fix: $150 - $300 per door.
  • Recalls: 16V643000 - Ford Motor Company (Ford) is recalling certain model year 2014-2015 Ford Fusion and Lincoln MKZ vehicles manufactured July 01, 2013, to March 31, 2014, and 2014-2016 Ford Fiesta vehicles manufactured June 01, 2013, to June 30, 2015. A component within the door latches may break.

Interior

• Sunroof Leaks
  • Description/Symptoms: Water leaks from the sunroof area, potentially damaging the headliner and interior components.
  • Solution: Cleaning the sunroof drain tubes or resealing the sunroof assembly.
  • Estimated Cost to Fix: $100 - $500+ depending on the severity of the leak and required repairs.
  • Recalls: None Found

Summary

The 2016 Ford Fusion is a generally reliable vehicle, but potential buyers should be aware of certain common issues. The 1.5L EcoBoost engine, in particular, has a known issue with coolant intrusion which can be a very costly repair. Other issues, like turbocharger failures and transmission problems, can also result in significant repair bills. Electrical problems with the SYNC system and battery drain can be frustrating. While the door latch recall is a known issue, it only covers specific model years and a limited range of production dates. Carefully inspect any used 2016 Fusion for these potential problems before purchasing.