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Welcome, I'm Chris (aka Moose).
Just to make sure, even buckling the seat will not turn off the seat belt minder?
Try to figure out if you are trying to make it work right or make is so you do not have to wear your seat belt?
Can you double check the years and models. Ford did not make a Fusion till 2006. The seat you used, was it from a collision car and was that same seat belt used?
At the seat belt buckle, key on is the yellow wire showing 5 volts and the brown wire ground?
Monitor the voltage on the yellow wire with the buckle connected and not connected. It should show voltage then no voltage. See if you get this result. If not then there is a buckle switch failure. It works identical for both years.
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