My daughter has an 07’ 2.3l Fusion that has an idler pulley bolt that breaks repeatedly. Seems like it happens once every 6 weeks. I put a nut on the backside of the bolt this time but it didn’t make a difference. I have checked everything else and no other pulleys are seized. I personally think it’s a poor design. I tried getting an answer from ford but they said if there was no service bulletin or recall (which there hasn’t been of either), then it didn’t have anything to do with safety…. I’m at my wits end and hate to part with the car cause it’s a nice little unit, but it’s getting annoying changing this thing repeatedly. I know this happens to others as well. The only other thing to try I’m guessing is either a longer belt, or some type of homemade bracket if one exists. If any of you have found a solution please let me know.
