Buy Ford Fusion Radiator Support

Quick Summary

A radiator support-also called a core support, upper tie-bar, or front-end module-is the metal or composite frame that cradles the radiator, condenser, cooling fans and front lamps on every Ford Fusion. It ties the left and right frame rails together, keeps the hood and fenders aligned, absorbs front-end crash loads, and even provides mounting points for sensors that power safety tech. When it bends, rusts, or cracks, owners can see coolant leaks, crooked headlights, and big hood gaps.

Fit & Years

• First generation (2006-2012)-steel core support with bolt-on upper bar; limited use of plastics. (Cars.com)
• Second generation (2013-2020)-lighter design; hybrids and plug-ins use extra brackets for high-voltage cooling; 2017-up cars gained stronger bumper beam and revised support geometry for crash safety. (IIHS)
• All gasoline, hybrid, plug-in hybrid, and Sport (2.7 L) trims share the same overall mounting points, but engine-specific bushings and air-deflector clips vary.

Construction

• Most Fusion supports combine stamped steel uprights with a plastic or composite lower cradle to cut weight and stop rust. (WardsAuto)
• Key welds sit at factory seams; sectioning in the middle is not approved by Ford service data. (oem1stop.com)
• The support also houses the hood latch, headlamp aiming pads, active-shutter motor, and parking-sensor brackets on higher trims. (I-CAR)

Warning Signs

• Coolant puddles or higher engine temps.
• Large gap between hood and grille. (Ford Fusion Forum)
• Headlights that no longer line up or shake while driving. (YourMechanic)
• Clunking when hitting bumps-the core support may be cracked at its bushing towers. (YouTube)

Typical Damage

• Minor fender-bender: front tie-bar bends but lower cradle survives.
• Severe crash: complete assembly buckles, protecting the cabin but requiring full replacement. (YouTube)
• Road-salt corrosion: 2013-16 cars in "salt belt" states faced a steering-assist recall linked to front-end rust; same moisture can attack the support. (NHTSA Static)

DIY Overview

1. Disconnect battery and drain coolant.
2. Remove bumper cover, headlamps, and active-grille shutter plug.
3. Support radiator/fans with wire or a jack so they don't drop.
4. Unbolt the upper tie-bar and side brackets, then lift the support forward. (YouTube)
5. Transfer clips, rubber insulators, and hood latch to the new frame before re-install.
6. Refill coolant, bleed air, and road-test. Detailed step-by-step is in Ford's workshop manual. (workshop-manuals.com)

Pro-Level Notes

• Ford specifies replacing certain self-piercing rivets with new SPR or blind rivets of equal grade. (oem1stop.com)
• After support replacement, calibrate forward-collision radar (if equipped) and headlamp auto-level. (I-CAR)
• Torque the upper-bar to rail bolts to 35 N·m and the lower cradle mounts to 80 N·m (generic Ford spec-always verify in current service info). (workshop-manuals.com)

Cost & Time

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Prevention Tips

• Rinse winter salt from the sub-frame.
• Inspect bushings yearly; worn rubber lets the core support flex and crack.
• Fix coolant leaks fast-antifreeze on painted seams speeds corrosion. (SAE International)

Related Parts

Radiator hoses, fan shroud, condenser, active shutters, bumper reinforcement, and hood latch all bolt to the core support-replace damaged pieces together to save labor. (YourMechanic)

Frequently Asked Questions

Q: What does a radiator support do?
A: It's the backbone that holds the radiator and condenser, keeps the front frame rails square, and sets hood and fender alignment. (WardsAuto)

Q: Is it safe to drive with a bent core support?
A: No. A bent frame can let the radiator rub the fan or leak coolant, and it weakens crash protection. (YourMechanic)

Q: Steel or plastic-what's better?
A: Steel is tougher against direct hits; composite lowers weight and never rusts. (WardsAuto)

Q: Do I need a Fusion-specific part?
A: Yes. Even small year-to-year changes in mounts mean a Taurus or Escape support will not fit. (Cars.com)

Q: Can I weld cracks?
A: Ford says replace, not repair, because welding distorts the thin metal and cancels corrosion coatings. (oem1stop.com)

Q: Will airbags or sensors be affected?
A: Modern Fusions mount radar and temperature sensors on the support; after replacement they may need calibration. (I-CAR)

Q: How long does the job take?
A: A trained tech can swap the whole assembly in half a day; DIY time is usually a full weekend. (YouTube)

Q: What tools are required?
A: Basic metric sockets, plastic fastener pliers, drill for rivets, torque wrench, and jack stands.

Q: Do hybrids use a different support?
A: The frame is the same, but hybrids add brackets for high-voltage cooling lines.

Q: Why does my hood sit high on one side?
A: The tie-bar may be twisted; loosen hinge bolts, align, or replace the support. (Ford Fusion Forum)

Q: Could a fender-bender harm steering?
A: Yes-NHTSA notes rust and impact at the front end can stress steering gear mounts. (NHTSA Static)

Q: Are aftermarket supports as strong?
A: Strength depends on gauge and weld quality; look for CAPA-certified steel thickness equal to Ford specs.

Q: Does replacing the core support affect warranty?
A: Using proper parts and following Ford repair steps keeps warranty coverage on related systems.

Q: Do I need an alignment afterward?
A: If you loosen sub-frame bolts, get a 4-wheel alignment to keep tire wear even.

Q: How do I keep it from rusting again?
A: Spray wax-based cavity sealer inside the seams each fall and rinse the front sub-frame often.

References

1. YourMechanic Q&A-Radiator support repair advice. (YourMechanic)
2. 1A Auto YouTube-2013-20 Fusion radiator replacement walkthrough. (YouTube)
3. IIHS-2020 Fusion crash-test structure update. (IIHS)
4. FordFusionForum-Owner thread on hood gap and bent support. (Ford Fusion Forum)
5. NHTSA Recall 19V632-Corrosion in 2013-16 Fusion front sub-frame. (NHTSA Static)
6. Ford Workshop-Manual excerpt-Front end service steps. (workshop-manuals.com)
7. I-CAR OEM News-ADAS calibration after front-end repairs. (I-CAR)
8. WardsAuto-Composite radiator support load functions. (WardsAuto)
9. SAE Cooling Systems Text-Importance of sealing seams against coolant. (SAE International)
10. Cars.com-Fusion generation overview 2006-2020. (Cars.com)
11. YourMechanic-Stay rod vs modern support article. (YourMechanic)
12. YourMechanic-How to replace a car radiator (cost factors). (YourMechanic)
13. Ford OEM1Stop PDF-Radiator support must be replaced at factory seams. (oem1stop.com)
14. YouTube DIY failures-Common Fusion front-end issues. (YouTube)

These numbered citations provide direct outbound resources for deeper reading while keeping your content trustworthy and comprehensive.