The company's Flat Rock, Mich., plant near Detroit will start making the Fusion Thursday. Ford hired a second shift of 1,400 new workers to make the Fusion at the plant, which also makes the Mustang sports car.
The plant will be able to produce 350,000 Fusions per year, 30 percent more than Ford makes at its plant in Hermosillo, Mexico.
The Fusion is one of the best-selling cars in the U.S. Sales this year are up 13 percent to 181,668 through July.
The Flat Rock plant was built by Mazda Motor Co. in 1987 and became a joint venture with Ford in 1992. Mazda stopped making vehicles in Flat Rock last year after the companies severed ties.