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The problem isn't you it the crappy Ford transmission. I have a 2011 Fusion with the same 6 speed manual transmission. Around 50,000 miles the synchros start to go bad. It starts with the first/second gear synchro then slowly progresses to the third/ fourth gear. Reverse gets to be a bitch too. I ended up putting a used transmission in last year but am now having the same issues with it. I only went with used because at the time Ford had no replacement or repair parts available. Ford couldn't even provide a clutch kit at the time, they were "in engineering." Ford won't admit that there is a problem with their 6 speed manual. At this point I am looking into switching to a 5 speed manual from a first generation Fusion. My first Fusion was a 5 speed manual and it was bulletproof.

Has anyone swapped a 5 speed manual in place of a 6 speed manual? If so what does it take?

Had a similar problem on my 08 Fusion. The dealer couldn't figure it out and wouldn't warranty my battery. Went outside one cold morning and noticed the windshield was frosted over everywhere except the middle. Turns out the stereo was bad and the current draw caused it to get warm even when the car was off.

My 2011's manual transmission started loosing its sycro's for 1st and 2nd gear just as the warranty ran out. The transmission was complete junk by 90,000 miles. I had the local dealership install a used transmission last July. At that time Ford had no repair parts or replacement transmission available. Ford could not even provide a replacement clutch at the time. The used transmission now has about 50,000 miles on it and is starting to have the same problems as the original one. I have contacted Ford and opened a case on it. Currently waiting to hear from Ford on a resolution. Has anyone else had a problem with the 6speed manual transmission and has Ford done anything for you? I find it unacceptable that Ford had no ability to repair my vehicle last year, forcing me to have a used transmission and aftermarket clutch installed.