🔧 Fusion - Starter Motor Replacement

Replacing the starter motor on your Fusion means removing the old electric motor that cranks the engine, then installing a new one in the same location. On the 2.5L engine, the starter is mounted low on the engine/transmission area, so safe lifting and battery disconnection are very important.

Difficulty Level: Intermediate | Estimated Time: 2-3 hours

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⚠️ Safety & Precautions

• ⚠️ Disconnect the negative battery cable before touching the starter wiring. The main starter cable is always high-current and can spark badly.
• ⚠️ Let the engine and exhaust cool completely before working underneath your Fusion.
• ⚠️ Support the vehicle with jack stands only. Never work under a vehicle supported only by a floor jack.
• ⚠️ Wear safety glasses because dirt and rust can fall while working underneath.
• ⚠️ If your Fusion has any stored radio presets or clock settings, they may reset after battery disconnection.

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🔧 Required Tools

You'll need the following tools for this repair:

• 10mm socket
• 13mm socket
• 15mm socket
• 8mm socket
• 3/8-inch drive ratchet
• 3/8-inch drive extension set
• Torque wrench 10-100 Nm
• Flat-blade screwdriver
• Trim clip removal tool
• Floor jack rated 2-ton minimum
• Jack stands rated 2-ton minimum
• Wheel chocks
• Mechanic gloves
• Safety glasses
• Shop light

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Starter motor - Qty: 1
• Starter mounting bolts - Qty: 2 if corroded or damaged
• Battery terminal cleaner - Qty: 1
• Dielectric grease - Qty: 1

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📋 Before You Begin

• Park your Fusion on level ground and shift to Park.
• Set the parking brake firmly.
• Place wheel chocks behind the rear wheels. Wheel chocks are wedge blocks that keep the car from rolling.
• Open the hood and let the engine cool.
• Disconnect the negative battery cable before lifting the vehicle.
• Raise the front of the vehicle and support it securely with jack stands.
• Use a shop light to locate the starter near the lower engine/transmission bellhousing area.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Disconnect the Battery

• Use a 10mm socket and 3/8-inch drive ratchet to loosen the negative battery terminal clamp.
• Remove the negative cable from the battery and position it so it cannot spring back onto the terminal.
• Black cable comes off first.

Step 2: Raise and Support the Front of the Vehicle

• Place wheel chocks behind the rear wheels.
• Use a floor jack rated 2-ton minimum to lift the front of your Fusion at the proper front jacking point.
• Place jack stands rated 2-ton minimum under the approved front support points.
• Gently lower the vehicle onto the jack stands and lightly shake the vehicle to confirm it is stable.

Step 3: Remove the Lower Splash Shield if Equipped

• Put on safety glasses before working underneath.
• Use an 8mm socket, 3/8-inch drive ratchet, and trim clip removal tool to remove the lower engine splash shield fasteners.
• Use a flat-blade screwdriver to gently release stubborn plastic clips if needed.
• Set the splash shield and fasteners aside in order.

Step 4: Locate the Starter Motor

• Use a shop light to find the starter on the lower side of the engine where it meets the transmission.
• The starter is a small cylindrical motor with a large battery cable and a smaller control wire attached to it.
• Take a photo before removal.

Step 5: Remove the Starter Electrical Connections

• Use a 13mm socket, 3/8-inch drive ratchet, and 3/8-inch drive extension to remove the nut from the large starter battery cable terminal.
• Move the large cable away from the starter.
• Use an 8mm socket or 10mm socket as fitted to remove the small starter solenoid wire nut, or unplug the connector if your replacement style uses a push connector.
• A solenoid is the small switch on the starter that engages the starter gear.
• Do not pull on the wire itself. Hold the connector or terminal end.

Step 6: Remove the Starter Mounting Bolts

• Support the starter with one hand because it can drop when the bolts come out.
• Use a 13mm socket or 15mm socket, 3/8-inch drive ratchet, and 3/8-inch drive extension to remove the starter mounting bolts.
• Keep track of bolt locations if the bolts are different lengths.
• Lower the starter out of the vehicle carefully.

Step 7: Compare the Old and New Starter

• Place both starters side by side on a clean surface.
• Confirm the mounting ears, electrical terminals, and gear end match.
• Use battery terminal cleaner to clean dirty cable eyelets before reinstalling.
• Apply a very light film of dielectric grease to the electrical terminal areas after cleaning. Dielectric grease helps protect electrical connections from moisture.

Step 8: Install the New Starter

• Raise the new starter into position by hand.
• Start the mounting bolts by hand first to avoid cross-threading.
• Use a 13mm socket or 15mm socket, 3/8-inch drive ratchet, and 3/8-inch drive extension to snug the bolts evenly.
• Use a torque wrench 10-100 Nm to tighten the starter mounting bolts to Torque to 48 Nm (35 ft-lbs).

Step 9: Reconnect the Starter Wiring

• Install the large battery cable onto the starter terminal.
• Use a 13mm socket and torque wrench 10-100 Nm to tighten the large starter terminal nut to Torque to 12 Nm (106 in-lbs).
• Reconnect the small solenoid wire.
• Use an 8mm socket or 10mm socket and torque wrench 10-100 Nm to tighten the small terminal nut to Torque to 5 Nm (44 in-lbs) if nut-retained.
• Make sure the wiring is not touching the exhaust or any moving parts.

Step 10: Reinstall the Lower Splash Shield

• Position the splash shield back under the engine.
• Use an 8mm socket, 3/8-inch drive ratchet, and trim clip removal tool to reinstall the screws and clips.
• Snug the small splash shield screws gently. Do not overtighten plastic fasteners.

Step 11: Lower the Vehicle

• Use the floor jack rated 2-ton minimum to lift the vehicle slightly off the jack stands.
• Remove the jack stands rated 2-ton minimum.
• Lower the vehicle slowly to the ground.
• Remove the wheel chocks.

Step 12: Reconnect the Battery

• Use a 10mm socket and 3/8-inch drive ratchet to reconnect the negative battery cable.
• Tighten the negative battery terminal clamp to Torque to 5 Nm (44 in-lbs).
• Make sure the terminal does not rotate by hand.

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✅ After Repair

• Start your Fusion and listen for a clean, strong crank.
• If the starter clicks but does not crank, recheck the battery charge and starter cable connections.
• If the starter does nothing, recheck the small solenoid wire connection.
• Check that no warning lights stay on after the engine starts.
• Reset the clock and radio presets if they were lost during battery disconnection.
• Take a short test drive, then recheck for loose splash shield fasteners or unusual noises.

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💰 DIY vs Shop Cost

Shop Cost: $450-$750 (parts + labor)

DIY Cost: $160-$350 (parts only)

You Save: $290-$400 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.5-2.5 hours.

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