I personally loved the car until I became victim of the 50k + transmission defect. There is a big problem with these transmissions. The car becomes outright dangerous to drive. Symptoms include, violent jerking when trying to accelerate to pass, followed by loss of speed. At times the tranny with simply drop out of gear, as if it went into neutral while cruising along on the express way. That's always fun when there is a semi on your tail. There are ALLOT of complaints to Ford and government agencies, but they refuse to do anything about a known defect in certain transmission that is extremely unsafe.
I bought this car at 34,000 in 2009. At the time I was a service technician and had to use my own car. Before the end of the 2 year mark I had put over 100,000 miles on this thing. I live in Ohio and drove this car to the Carolinas and Virginia beach annually, including a 24 hour straight drive to Texas and 24 hours straight back 3 days later and never felt worried about making it home. My point is, I beat up my vehicles and this has been a beast. AC failed around the 140,000 mark (didn't bother fixing it), I replaced the thermostat and drive belt at 150,000, at 210,000 the radiator and transmission cooler lines were replaced, driver side window regulator at 215,000 and now at 217,000 the transmission valve body needs to be replaced so I'm reluctantly trading it in before I press my luck any further. I can't talk much about labor cost because I do most of my own work, but replacement part costs aren't terrible (except the valve body). And even with the age of the car its still averaging 27mpg! My biggest cons are the cheap plastic door handles and the radio display has bad soldering causing it to blank out. Basically very minor things. Ford bought my favor back from GM with this car.
I purchased this car new in 2006 when I needed to trade in my mustang that was not so affordable while in college. This was not my choice vehicle, but the decent power was an acceptable transition from the GT power I was used to indulging in. I pushed the oil changes beyond to ~5k mi but regularly went with a synthetic oil option. I did maintenance at 80k mi and have it inspected periodically. It now has 140k mi and the recent full inspection from the dealership reported all areas in the green, including belts and hoses. That's the good. Here's the bad. Shortly after purchase, one of the rear inner door handles completely broke. They're made of plastic that isn't so durable. I should have taken it for repair under warranty, but didn't. Then, at ~80k mi, the front control arms needed to be replaced. This was a bit expensive... on the order of $1800. It wasn't a safety concern, but they were noisy. It was due to the rubber in the ends of each arm, which breaks down so it sounded like rubber rubbing together whenever the wheels were turned. That was a bummer, but I suppose the bad could have been much worse. The headliner has started to fall at the rear recently, so that will need repair next. Other than that, I've only needed to replace the brakes - which lasted >100k mi and tires. Overall it's been a great, reliable vehicle for the past decade!
We bought ours brand new in 2006, it was a demo vehicle so it already had 3,000 miles on it, it is now 2015 and our car only has 80,000 miles on it, just had its first tune up, THESE FUSIONS NEED A TUNE UP BEFORE 100,000 MILES OTHERWISE SERIOUS PROBLEMS MAY OCCUR, we had friends who learned that the hard way. this car is only the 4-cylinder model but it doesn't seem as slow as everyone makes it out to be, and its been unbelievably reliable, only needed regular maintenance and a sense that had to be replaced at about 50,000 miles. Perfect midsized car.
I do not even have 70k miles on my 2006 Fusion and my transmission went out as well. Drove fine unless you needed to get on the interstate or get into Overdrive gear - would then jolt, rpms up to 5 and 6 without accelerating one bit. Now I'm having to pay over $2400 to replace it. With as many reviews as I've read since this happened to me (more than I thought with this same issue!) this definitely needs to be a Recall from Ford or at least some kind of compensation when they are aware there is an issue with these models!! Before this happened I absolutely LOVED this car, now I am a little leary about the Fusion models in general.