🔧 Fusion - Starter Motor Replacement

Replacing the starter motor on your Fusion means safely disconnecting the battery, accessing the starter near the lower engine/transmission area, removing the electrical connections, and swapping the starter assembly. The starter turns the engine over when you press the start button or turn the key, so a failed starter can cause a no-crank condition.

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

---

⚠️ Safety & Precautions

• ⚠️ Disconnect the negative battery cable before touching the starter wiring. The starter has a direct battery-power cable.
• ⚠️ Let the engine and exhaust cool fully before working underneath your Fusion.
• ⚠️ Support the vehicle with jack stands. Never work under a vehicle supported only by a floor jack.
• ⚠️ Wear safety glasses and gloves. Dirt and rust often fall when working under the engine bay.
• ⚠️ Keep the key/fob away from the vehicle while working so the starter circuit cannot be activated accidentally.

---

🔧 Required Tools

You'll need the following tools for this repair:

• 10mm socket
• 13mm socket
• 15mm socket
• 8mm socket
• 3/8-inch ratchet
• 3/8-inch extension set
• Universal joint socket adapter
• Torque wrench 5-80 ft-lbs
• Flat-blade screwdriver
• Trim clip removal tool
• Floor jack rated 2-ton minimum
• Jack stands rated 2-ton minimum
• Wheel chocks
• Work light
• Mechanic gloves
• Safety glasses

---

🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Starter motor - Qty: 1
• Starter mounting bolts - Qty: 2, replace if corroded or damaged
• Battery terminal corrosion protection spray - Qty: 1

---

📋 Before You Begin

• Park your Fusion on level ground and set the parking brake.
• Place wheel chocks behind the rear wheels.
• Open the hood and allow the engine to cool completely.
• Disconnect the negative battery cable using a 10mm socket. The negative terminal is marked with a minus symbol.
• Wait at least 2 minutes after disconnecting the battery before working near the starter wiring.
• Raise the front of the vehicle with a floor jack rated 2-ton minimum and support it with jack stands rated 2-ton minimum.
• A universal joint socket adapter lets the socket bend slightly so you can reach awkward starter bolts.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Disconnect the Battery

• Use a 10mm socket to loosen the negative battery terminal clamp.
• Lift the negative cable off the battery post and move it aside so it cannot spring back.
• Wrap the cable end with a clean rag if needed to prevent accidental contact.
• Battery off first, always.

Step 2: Raise and Secure the Vehicle

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

Step 3: Remove the Lower Splash Shield

• Use a trim clip removal tool to remove plastic push clips from the lower engine splash shield.
• Use an 8mm socket to remove any small shield screws.
• Lower the splash shield and set it aside.
• A splash shield is the plastic panel under the engine that protects components from water and road debris.

Step 4: Locate the Starter Motor

• Use a work light and look at the lower engine/transmission area on the front side of the drivetrain.
• The starter is a small cylindrical motor mounted where the engine meets the transmission.
• Identify the large battery cable and the smaller control wire attached to the starter solenoid.
• The solenoid is the smaller cylinder on the starter that switches battery power to the starter motor.

Step 5: Remove the Starter Electrical Connections

• Use a 13mm socket to remove the nut from the large battery cable terminal on the starter.
• Pull the large cable straight off the stud and move it aside.
• Use a flat-blade screwdriver to gently release the locking tab on the small control-wire connector.
• Pull the small connector straight off. Do not pull on the wire itself.
• Take a photo before removal.

Step 6: Remove the Starter Mounting Bolts

• Support the starter with one hand before removing the final bolt. It is heavier than it looks.
• Use a 15mm socket, 3/8-inch ratchet, and 3/8-inch extension set to remove the lower starter mounting bolt.
• Use a 15mm socket with a universal joint socket adapter if the upper bolt is difficult to reach.
• Remove the upper starter mounting bolt.
• Lower the starter carefully from the vehicle.

Step 7: Compare the Old and New Starter

• Place both starters side by side on the ground.
• Confirm the mounting ears, electrical terminals, and gear nose position match.
• Use a clean rag to wipe dirt from the starter mounting surface on the transmission.
• Do not apply grease to the starter gear or mounting face.

Step 8: Install the New Starter

• Position the new starter against the transmission mounting surface by hand.
• Start both mounting bolts by hand first to avoid cross-threading.
• Use a 15mm socket, 3/8-inch ratchet, and 3/8-inch extension set to snug both bolts evenly.
• Use a torque wrench 5-80 ft-lbs with a 15mm socket to tighten the starter mounting bolts to Torque to 48 Nm (35 ft-lbs).

Step 9: Reconnect the Starter Wiring

• Push the small control-wire connector onto the starter solenoid until it clicks.
• Install the large battery cable onto the starter terminal stud.
• Use a 13mm socket to install the terminal nut.
• Use a torque wrench 5-80 ft-lbs with a 13mm socket to tighten the starter cable nut to Torque to 12 Nm (106 in-lbs).
• Make sure the cable does not touch the exhaust, axle, or any moving part.

Step 10: Reinstall the Lower Splash Shield

• Lift the splash shield back into place by hand.
• Use a trim clip removal tool to reinstall the plastic push clips.
• Use an 8mm socket to reinstall the shield screws.
• Tighten the small shield screws snug only. Do not overtighten plastic fasteners.

Step 11: Lower the Vehicle

• Use a floor jack rated 2-ton minimum to lift the vehicle slightly off the jack stands.
• Remove the jack stands rated 2-ton minimum.
• Lower your Fusion slowly to the ground.
• Remove the wheel chocks after the vehicle is fully on the ground.

Step 12: Reconnect the Battery

• Place the negative battery cable back onto the battery post.
• Use a 10mm socket to tighten the negative terminal clamp.
• Apply battery terminal corrosion protection spray if the terminal is clean and dry.
• Do not overtighten the battery terminal. It only needs to be secure and unable to twist by hand.

---

✅ After Repair

• Start your Fusion and listen for a clean, normal crank sound.
• If the engine does not crank, stop and recheck the battery terminals and starter electrical connectors.
• Let the engine idle for 1-2 minutes and make sure no warning lights remain on.
• Check that the lower splash shield is secure and not hanging down.
• Some one-touch window or clock settings may need to relearn after battery disconnect.
• If the starter still only clicks, have the battery and charging system tested before replacing more parts.

---

💰 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.

---

🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.