Do you want to know the best Ford Fusion mods to upgrade your ride? You are at the right place! But first, a few words about this spacious, sporty, and reasonably-priced sedan.
The Fusion is a well-rounded and affordable midsize sedan that the American automaker Ford introduced in 2006. Just after a few years into production, the sales improved tremendously, and Fusion started to impress the automotive critics. It gathered multiple awards in 2010, including Motor Trend Car of the Year nominee, and won the honor of North American Car of the Year. It was so well-received that in 2011, the USNews named it the best affordable midsize car for families. So spacious and comfortable that you can even live in it.
Besides it is one of the most reliable Ford cars you can buy with a J.D. Power rating of 87/100 (for the 2020 model year).
While it possesses a distinct, eye-catching exterior, well-designed & spacious interior, generous trunk space, pleasant ride, and sporty handling, owners still look for the best Ford Fusion mods (just as they seek the Prius mods) to stand out in the crowd and improve their drive’s handling and performance.
This post discusses all things about the modded Ford Fusion. It means we will talk about Ford Fusion tuning, Ford Fusion interior mods, Ford Fusion sport mods, Ford Fusion aftermarket parts, and so on.
Best Ford Fusion Mods for 2024
The Fusion remained a class leader in the sporty sedan segment for a long time, thanks to the changes the engineers made for every new model. However, there is still room to improve its styling, drivability, handling, continuously variable transmission, and performance.
It doesn’t matter if you are searching for the Ford Fusion body kit or Ford Fusion custom parts; you can find a huge variety of products for the interior, exterior, performance, lighting, wheels & tires, and automotive tools.
Handling and Suspension Mods
Handling and suspension mods for Ford Fusion are some of the most common for this sporty sedan. To improve handling, go for a 0.9 to 1.5-degree toe-out at the front and install a slightly negative camber.
You can drop your Fusion as much as you like, but we suggest you lower it by 30mm – 43 mm or go for an arch work for a more considerable drop. For shorter drops and to add a sense of style performance, install lowered springs and sway bars. These two things will not only drop the ride height for a more assertive posture but will also make the body roll and cornering better than the stock suspension. Pairing these adjustments with clean car seats enhances both the vehicle’s appearance and your driving comfort.
Swapping damaged bushings and shocks also lifts Fusion’s handling significantly. Tuners mostly employ poly bushes and coil-overs for this purpose.
Performance Mods
How to make my ford fusion faster, or can Ford Fusions be fast? These are pervasive questions from people seeking the best Ford Fusion mods. The possibilities for Ford Fusion tuning are endless. Below are some of the best Ford Fusion Mods for performance.
1. Internal Powerplant Modifications
Improving your engine output requires changes to crank, pistons, conrods, and compression ratio. The connecting rods and pistons are ideal for larger turbos. Find and install durable, high-quality H-beam or I-beam rods and forged pistons to witness a huge power boost.
In addition, you can install fast road camshafts to boost performance, but only an expert mechanic must do it. These camshafts are not easy to come by, so you need a professional who can regrind the stock ones.
2. Low Mass Flywheel and Wheel Hop
A lesser mass flywheel has the tendency to enhance Fusion’s free-revving ability. Furthermore, you can eliminate the wheel hop by modifying the axis of rear engine movement through a solid rear motor mount.
3. Fuel Upgrades
Larger injectors and performance fuel pumps can be great upgrades if you’ve made other modifications and are facing fuel starvation issues. Also, a faster-flowing fuel pump on its own won’t make much of a difference. To fix a lean condition, you should increase the fuel pressure by adjusting both your fuel pressure regulator and check valve, then try to provide more fuel to the engine.
Simply installing a fuel pump with a 100 liters/second flow rate won’t be effective since the fuel pressure regulator restricts the amount of fuel that flows. More fuel needs more air to keep the proper fuel-to-oxygen ratio, so getting the fueling correct is crucial. Another upgrade is switching to a different type of fuel; higher octane or cetane fuels often provide a bit more power. Converting to Methanol or Nitro fuels can significantly boost power but involves a more complex upgrade.
4. Forced Induction Upgrades
There is no doubt that a turbocharger will increase the air intake, thus permitting the engine to burn more fuel and improve performance. While it is one of the best Ford Fusion mods, it is also the most complex.
Another thing you can do with a turbo to enhance power output is to install a turbo spool with a downpipe. The faster will be the expelling of the hot air; the quicker will be the turbo spool, enhancing the horsepower and torque as a result. You can achieve this by adding a bigger downpipe, selecting from catted and off-road. The catted would be an ideal choice until you want your Fusion to hit the racetrack.
Additionally, you can ensure your engine performs optimally by using high-quality car oil that reduces friction and improves efficiency.
5. Air Induction Kits and High-flowing Exhausts
Again, you will get plenty of options for both induction kits and exhausts. For instance, a cold air intake system allows more air, and a performance exhaust will give you a significant horsepower boost. In some cases, the exhausts and kits may improve the power output only after eliminating a restriction.
Remember that a good air induction kit can only improve performance if your Fusion’s current air intake is not working properly. Moreover, understand that this kit won’t be beneficial for small power plants. However, if you have made several changes to your mill and it requires increased air, then you should use an induction kit.
The best way forward in this regard is a full induction kit with a cold air feed. Employ a panel air filter instead of a paper filter for effortless cleaning and maintenance. We also suggest avoiding a big exhaust because it can reduce the exhaust rate.
Many might view a modified exhaust on a family sedan as unnecessary, but the Fusion has always stood out in that regard. With its sleek design and powerful engines, the Fusion offers excellent exhaust options to enhance your driving experience. While they may not be considered “affordable” by some, these exhausts are genuine upgrades that elevate the car’s performance. If you’re looking to transform your Fusion into a sport sedan that turns heads, the MagnaFlow CatBack Exhaust is a top choice, delivering a deep, resonant tone for your 3.0 or 3.5 liter V6 engine.
6. Remaps
Go for a remapped electronic control unit to improve your vehicle’s performance. You can also easily find aftermarket ECUs (like the ones offered by SuperChips) and inline tuning boxes from the market.
You can also try Fusion ECU tuning files from ECUMap.
7. Brake Mods
Installing the performance upgrades and not fitting high-performance brake pads will be counterproductive in your modification journey to own the best tuner car. Therefore, your Fusion would require better disc brakes with improved stopping power. Avoid using race brake pads because they are noisier than conventional ones and require a warm-up to work effectively. Try brake pads from GoodYear Brakes that come with 3 years or 36,000 miles of warranty.
8. Alloy Wheels
Choosing the right size of wheels and tires is crucial for Fusion’s improved performance. Select alloys that are lightweight with a suitable design for brake cooling. Similarly, a soft tire of the right size is essential for improved handling and performance. A larger-than-recommended tire will increase road drag, so it won’t be beneficial if your goal is enhanced performance.
Some experts recommend a maximum of 19 inches for the US-bound Fusion, but we say you should fix 18-inch tires for optimal fuel efficiency and performance. To complete the sleek look, opt for cool designs for your alloy wheels that make your Fusion stand out.
9. High Performance Tires
Ensuring optimal tire performance is crucial for your safety and driving experience. Cheaper or old tires are dangerous and can significantly affect handling, especially in wet conditions. While performance tires excel in dry conditions, some all-round options exist for the Ford Fusion. Selecting high-performance tires requires consideration of tread patterns and weather conditions. Ideally, having separate sets for dry and wet weather is best, with a bias towards wet weather tires, especially in the Northern Hemisphere.
Tread patterns like directional ‘v’ and asymmetric designs offer good compromises between wet and dry performance. Adhering to manufacturer recommendations for tire types and pressures is essential. Avoid mixing different tires on the same axle and prioritize placing new tires on the rear to prevent oversteer. Regularly checking tire pressure and balancing wheels ensures predictable handling and longevity for this good-looking car from Ford.
Related Guide: What are Car Axles – A Detailed Guide!
10. Performance Clutch
The clutch’s role in transferring engine power to the wheels while allowing gear changes is crucial. A slipping clutch is a common Ford Fusion problem that diminishes power and requires a strong grip and quick response. Higher engine torque makes it harder for the clutch to engage, leading to slipping. Power and performance clutches feature high-friction surfaces and multiple contact plates for durability. Race clutches, while powerful, can be challenging to drive smoothly in traffic or on hills due to their abrupt engagement.
Proper alignment is crucial for clutch longevity, especially in high-performance setups. For everyday driving in the Fusion, a fast road power clutch is recommended over a multi-plate race solution, which is better suited for high-power applications. Clutch slip occurs when engine power exceeds the clutch’s rating, leading to premature wear and potential failure. While the Fusion clutch replacement can be straightforward with the right tools, some vehicles require extensive disassembly.
11. Quick Shift Gear Stick Upgrade Kits
The gearstick connects to the gearbox through a lever system. Beneath the gate, there’s a pivot, and the lower end of the lever handles gear shifts. Quick shift levers sometimes have a bend; this helps with leverage while keeping the knob position steady. Basic physics: a shorter top section and a longer bottom section mean faster shifts. It takes more effort, but no gearbox should resist shifting unless it’s malfunctioning. After driving a Fusion with a quick shift, going back to a standard stick feels like a step back.
Many quick shift kits exist, so pick one that is adjustable to your liking. Gearboxes vary, and the fastest setting might cause clearance issues. Once installed, test each gear. If rubber components interfere, you might need to trim or adjust. Driving with a quick shift, the gear lever’s travel is noticeably shorter—sometimes by 40%—resulting in faster, smoother shifts. Installation is fairly easy. Follow the kit’s instructions or check a Fusion workshop manual. The car will feel sportier, even if the actual performance remains unchanged.
12. Fast Rod Camshafts
Camshafts are a popular choice when upgrading a Ford Fusion. Lots of companies, both in the U.S. and the U.K., specialize in making fast road cams for Ford engines. These cams, designed specifically for performance, tweak the duration of the intake and exhaust timing in the engine’s valves. This adjustment can boost horsepower noticeably.
Honestly, it’s one of the more effective mechanical modifications you can just bolt on. Whether your engine is turbocharged or naturally aspirated, you might see gains of around 10% with the right cam setup. However, there’s a trade-off. If you go for an overly aggressive camshaft, the engine may idle unevenly—some call it a “lumpy” tick-over. This can make daily driving tricky, so striking the right balance is crucial.
Other Ford Fusion Mods
These are just a few of the best Ford Fusion Mods. Dependable used cars like the Ford Fusion allow for versatile modifications while remaining budget-friendly. There are plenty more for the exterior and interior. For exterior decorations, you can add a custom grille, a body kit, towing and hitches, new head- & taillights, a spoiler, wind deflectors, a roof rack, a bike rack, mud flaps, custom horns, and so on.
Additionally, adorn the interior with new floor mats, seat covers, a steering wheel, shift knob, pedals, cargo liners, a dash kit, etc.
Get cheap mods for Ford Fusion or go for luxurious ones; the choices are limitless.