Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2006 Ford Fusion owners, lightly cleaned up (personal details are redacted by NHTSA).
I was parking in a bettendort, iowa restaurant parking lot when my car surged forward. I applied the brakes, but car would not stop. It left the parking lot, crossed a sidewalk and went onto a street near an intersection. I kept applying the brakes, but car still wouldn't stop. It collided with an oncoming car, crossed over a median and finally stopped on another street across from the intersection.
[redacted] : the inside door handle broke on front passenger side and driver side. They have been breaking for over two years now. The price to fix this is going to be 243.50 and the Ford motor company will not fix it and will not give a percentage off. I am not the only one who is having this problem. It is all over the internet ways to fix this problem because Ford will not fix. Or do anything. This is a safety hazard if you have a wreck or emerge in water you would not be able to get out. I think your department needs to get involved....they recall the Ford f150 for the same thing, I am 68 years old and if I get into a wreck they will be no way for me to get out of my car.
Interior front door latches broke around the 100,000 mileage. All four electric window regulators/motor have failed from the 80,000-110,000 mileage period. Each of the regulators plastic rollers where the cable goes around were broken. Two of the automatic door locks quit working as well. All motor mounts have been replaced at least once and 2 have been replaced twice each. 4-cylinder. I have seen 100's of complaints online about the motor mounts and many for the interior latches and window regulators. I have spent over a thousand dollars on the motor mount issues.
Tl* Takata recall. The contact owns a 2006 Ford Fusion. The contact stated that the passenger side air bag warning indicator illuminated. In addition, the interior driver side door handle fractured. The contact received notification of NHTSA campaign number: 16V384000 (air bags); however, the parts to do the repair were unavailable. The manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the issue. The failure mileage was approximately 48,000. VIN tool confirms parts not available.
When vehicle reaches 65 MPH a buffeting of the rear window is so loud that it seems as if it will break . Does not happen all the time. It happens even with the windows raised. I have a blanket stuffed between the rear dashboard and the window to quiet the buffeting. Owners manual refers to the problem and how to remedy it if the windows in the front compartment are down , but nothing if the windows are up. Never had this happen in the past with any vehicle . Very unusual .
Tl* the contact owns a 2006 Ford Fusion. When the contact attempted to exit the vehicle, the front driver side door handle failed to operate. As a result, the contact had to roll the window down to exit the vehicle. The vehicle was taken to a dealer where it was diagnosed that the driver side door handle needed to be replaced. The vehicle was repaired, but the failure recurred. The manufacturer was made aware of the failure. The failure mileage was 233,000.
Tl* the contact owns a 2006 Ford Fusion. The contact stated that the interior door handle fractured and prevented the contact from exiting the vehicle. The contact stated that the part was replaced three times on both the driver and passenger side door handles. The failure recurred multiple times. The vehicle was taken to the dealer where the door handle was replaced. The manufacturer was made aware of failure. The failure mileage was 48,000.
Tl* the contact owns a 2006 Ford Fusion. The contact stated that while driving 60 MPH, the driver's door opened while driving. The contact stated that this was a recurring issue. In addition, the contact stated that the air bag light remained illuminated. The manufacturer was made aware of the issue. The failure mileage was 127,000. ...updated 02/19/16
Tl* the contact owns a 2006 Ford Fusion. The contact stated that the interior door handle fractured on the driver and passenger sides of the vehicle. The failure recurred twice. The vehicle was taken to an independent mechanic, where the door handle was replaced. The manufacturer was made aware of the failure. The approximate failure mileage was 200,000.
Tl* the contact owns a 2006 Ford Fusion. The contact stated that the driver side door failed to open from the inside because the handle was fractured. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 119,000.
Body complaints in other Fusion years
Frequently asked questions
How common are body problems on the 2006 Ford Fusion?
NHTSA has 74 complaints about the body & structure of the 2006 Ford Fusion, 10% of the model year's 730 complaints. The component named most often is body › door (25 mentions).
Is there a recall for 2006 Ford Fusion body problems?
No. NHTSA lists no body & structure recall for the 2006 Ford Fusion, though it has 4 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2006 Ford Fusion body problems start?
Half of the complaints with a recorded mileage happened before about 62,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 0 fires and 3 injuries to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.