fairly significant
Typical Repair Cost:
No data
Average Mileage:
68,000 miles
Total Complaints:
1 complaints

Most common solutions:

  1. replace lid and paint (1 reports)
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problem #1

Jan 022017

Fusion SE 2.4L

  • Automatic transmission
  • 68,000 miles

click to see larger images

severe corrosion to trunk lid

I own a 2011 Ford Fusion I purchased new from the Hall Ford Dealership in Newport News VA. The problem is with the trunk lid. Earlier this year I noticed stains on the top of my Fusions rear bumper. I opened the trunk and was appalled at what I saw on the lower deck lid just on the inside. The entire bottom of the lid is bubbled with rust and towards the center of the lid the metal is badly damaged to where there is actually several holes in the metal and the fold on the inside is beyond repair. This obviously has a been going on for some time. I have since taken the vehicle to two body shops, one of which is a Ford authorized body shop. The first body shop told me the only way to truly permanently fix the damage was to replace the deck lid and repaint. Are you kidding me? Replacing the entire deck lid after 6 years. Furthermore, the technician told me they are seeing these issues with the newer 2014 mustang and other Ford vehicles. Primarily the F-150 and Explorer. The second body shop, the authorized Ford body shop, told me the exact same thing. The rear deck lid must be replaced and the damage is due to a defective manufacturing process. I have read on line that contaminants in the fold of the deck lid are causing the problem and prematurely destroying the trunk lid. The Technician told me that I was exactly correct and they are seeing newer vehicles with exact same problem and of course customers are irate due to the fact that the quality obviously does not meet customer expectations. The fact that I have to pay to replace the entire body panel on a 2011 to restore this damage is ridiculous. My son has a 2011 ford Fusion the exact same model. He lives in Charleston SC where the air is more humid. He told me there is no evidence of any corrosion on the inside trunk lid. Clearly I have a defect that originates with the manufacture. I own 3 vehicles. A 1996 Dodge Ram, 2009 Toyota Camry and the 2011 Fusion. Even the 1996 Dodge Rams body panels are intact with no rust. The rust on the Fusion trunk lid is greater than the other two vehicles combined. Ford should be held responsible for the repair since the trunk lid has prematurely failed due to: 1. Poor manufacturing process causing the metal to prematurely fail below the paint covering. I have had two body shops tell me this is clearly a defect in the fabrication process at the time the vehicle was built. Ford needs to make this right and fix it. I keep the vehicle waxed and clean so yes this is pretty aggravating to be told that the only way to repair the damage is to replace the entire trunk lid. Ford told me this incident is outside the 3 year warranty. I feel I should not have to replace the entire trunk lid at a substantial cost to rectify this problem. I have been told by two body shops the damage is too substantial and will come right back if the lid is not replaced. The fact that my son has the exact same year and model with no evidence of rust or bubbling paint clearly points to manufacturing process at the time the vehicle was fabricated. I was looking at replacing my truck with a new Ford Diesel but in good conscience I am not able to accept the fact that I may have to replace entire body panels within 6 years on a 60000 dollar vehicle. Since my 21 year old dodge diesel transmission failed, I elected to spend money on a re-manufactured transmission. I can honestly say I have no rust on this 21 year old dodge with original paint. Can Ford say that about a 21 year old Ford. Highly doubt it. I threw in the picture of my truck to show I am not making this up.

- Tommy T., Yorktown, VA, US