The 2006 Ford Fusion has 4 recalls, the most serious being a Takata airbag defect affecting both the driver and passenger sides, where the inflators can rupture and send metal fragments into the cabin, causing serious injury or death.
Both the driver-side and passenger-side front airbag inflators are affected by this issue. The propellant inside these inflators can degrade after prolonged exposure to heat and humidity, causing the inflator to explode rather than deploy correctly. When that happens, sharp metal pieces can strike the driver and any front passengers. This defect is particularly associated with vehicles in hot, humid climates and those in certain high-humidity U.S. territories, though any 2006 Fusion may be affected depending on where it has been registered or driven over its lifetime.
On the brake side, the anti-lock brake system's hydraulic control unit contains valves that can react with certain brake fluid formulations and fail to close fully. When that happens, the brake pedal travels further toward the floor than normal before the vehicle slows, which can extend stopping distance and raise the risk of a collision. This concern applies to the hydraulic control unit that manages ABS function, not the brake pedal or calipers themselves, so the brakes still work but may require more effort and distance to bring the car to a stop.
At a glance
What can fail
The driver's side air bag inflator may explode. This can happen when the propellant degrades after prolonged exposure to high heat, humidity, and temperature changes.
What the fix does
Dealers will replace the driver-side airbag inflator or module with a new one at no cost to you.
Summarized — see the official notice for exact wording, dates, and contacts.
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At a glance
What can fail
Brake fluid additives can react with valves in the ABS hydraulic control unit, preventing them from closing properly and affecting braking performance.
What the fix does
Dealer will flush brake system with DOT 4 fluid, install new reservoir cap, test the control unit, and replace it if a stuck valve is found.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The passenger front air bag inflator may rupture during a crash due to propellant breakdown from long-term exposure to humidity and temperature changes.
What the fix does
Dealers will replace the passenger front air bag inflator at no cost. Ford will mail recall notices and notify owners when parts are available.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The passenger front air bag inflator may rupture during a crash due to propellant breakdown from long-term exposure to humidity and temperature changes.
What the fix does
Dealers will replace the passenger front air bag inflator at no cost once parts become available.
Summarized — see the official notice for exact wording, dates, and contacts.
