Ciricvelibor/GettyDespite being discontinued after the 2020 model year, Ford Fusions are a dominant model in the used market, ranking seventh among used passenger cars in the fourth quarter of 2025, per Ford Authority. But while the Fusion may look like an affordable used sedan, its low purchase price could be concealing potentially expensive problems. American Automobile Association (AAA) reported that researchers examined more than 600,000 complaints submitted to the National Highway Traffic Safety Administration (NHTSA) between 2015 and 2024. The Fusion accumulated 16,335 complaints, more than any other vehicle in the study and ahead of the Ford F-150's 15,378 and the Ford Escape's 14,940.According to CarComplaints, steering trouble is the clearest pattern in the Fusion's complaint history, particularly among the problem-heavy 2010, 2011, and 2012 models. Airbag, engine, powertrain, and brake complaints also appear across those years. Some potential repairs can be expensive: RepairPal estimates a Fusion steering-rack replacement at around $3,000, while Kelley Blue Book's (KBB) estimator shows that replacing a Fusion transmission can exceed $5,000. Reliability concerns aren't limited to those older model years, either, as Consumer Reports placed the 2020 Fusion Hybrid among the hybrid cars that aren't very reliable, citing weaknesses in its build quality, powertrain, suspension, and steering.However, these were complaints logged during the study period, not complaints exclusively involving 2015 to 2024 model-year Fusions The analysis also combines multiple model years and problems under a single nameplate and doesn't adjust for how many of each vehicle are on the road. Still, the total is difficult to dismiss since the Fusion represented 0.8% of vehicles in operation in late 2023, compared with the F-150's 3.7%, yet accumulated more complaints during the study period.AdvertisementAdvertisementRead more: You've Been Warned: Consumer Reports Says These 9 Electric Vehicles Are The Least ReliableSome Fusion complaints could wipe out the value of older carsTony Savino/ShutterstockWith a steering rack replacement potentially costing around $3,000 and a transmission replacement exceeding $5,000, buyers should consider those expenses against what an older Fusion is actually worth. According to KBB, the 2010, 2011, and 2012 models, which are prone to issues, average about $3,000, $3,000, and $4,575, respectively, in resale value. A $3,000 steering repair could therefore wipe out 100% of the first two cars' value and about 66% of the 2012's. Even at $5,000, a transmission repair would equal roughly 167%, 167%, and 109% of those values, pushing each car beyond the point where repairs become not worth it.While some steering problems were covered by a Ford recalls, the campaign applied only to certain 2011 and 2012 Fusions, and steering gear replacement depended on the results of the dealer's inspection. Meanwhile, the 2010 received no equivalent recall even after a seven-year-long NHTSA investigation. Repairs that fall outside applicable recall or warranty coverage generally become the owner's financial responsibility. Even extended warranties might not be worth it because the warranty company may need to approve a repair before work begins and can exclude common problems.Ford also acknowledged coolant intrusion problems in certain 2017 to 2019 Fusions equipped with the 1.5-liter EcoBoost engine, which could require a short-block replacement. Free coverage for this issue was limited and only applies within seven years or 84,000 miles, meaning most are outside that window by 2026. One 2017 owner reported an $8,000-to-$11,000 dealer estimate on CarComplaints, roughly 98% to 134% of the $8,200 resale value KBB lists for a 2017 SE.AdvertisementAdvertisementFound this helpful? Subscribe to the Money Digest newsletter and unlock your financial potential. And add Money Digest to your preferred sources for smart money insights!Read the original article on Money Digest.