Thanks, everyone. I'll have a service tech ride with me the next time I drop it off at Ford. When this first started I tried removing every loose item in the car and completely emptying it out in hopes it was something in one of the doors or storage areas but of course I couldn't get lucky enough for that to be the issue. I've tried just living with the noise but the longer I hear it the more it irritates me.
Had the loose sun visor rattle on my 06 Fusion. Sounded like it was coming from the rear passenger door. Also drove me nuts. Always check the visors and the sunglass holder as well as the door bins and center console for loose things.
On the 2013+ the little plastic pieces behind the door handle can rattle. I stuck mine on with foam tape.
As propwash has indicated, these ghost sounds can be extremely hard to pinpoint. I remember when I first got my 2010 FFH and it was, and still is, very quiet. No rattles or squeeks anywhere. Then one day I hear this vibration which sounded like it was coming from the front passenger seat or glovebox. I searched and searched. Couldn't find where it was coming from and it was driving me mad as to why this started. Plus it wasn't making the noise all the time but just at certain speeds. Well eventually I notice the sun visor isn't pushed into it's holder and is vibrating at certain speeds. Whoever was in there must have used it and when moving it back to it's resting place didn't snap it in. Once in, no more vibration.
So I put the spare tire on. Admittedly, spare tires are not designed to be "quiet" so I expected some noise, but the noise was fairly constant and not the "pulsing" sound that I was getting with the O.E. tire. However, I now think that I have 2 issues. 1) The tire is bad, 2) my front rotors are warped a little. With the spare tire on, there was some pulsing sound, but VERY minimal compared to when I had the one particular regular tire on, and braking still had some pulsing too. When I removed the spare tire and put the other back on, the pulsing sound was there whether I was braking or not, and the braking pulsed more, plus I could "feel" the pulsing in the steering wheel with no braking applied.
So again, at least 1 bad tire, and probably new rotors (and brake pads even though they are far from worn). I didn't measure the tire tread depth, but they still have a lot of tread on them. We've had the car for about 18 months, so I am guessing that the previous owner already replaced the tires before we got the car and picked out the O.E. tire as replacement.
Local places are quoting nearly $900 for 4 of the General Altimax RT43 tires installed, and the price is a solid $1000 to go with the Continentals. That is a lot more than I've ever paid for tires for any vehicle before, including the performance Pirelli tires that I bought for a previous supercharged sporty car that I got rid of about a year ago. Must be a higher price due to the 18" size vs. 17" and 16" of my more recent vehicles.
Maybe there are other tires to consider???
You say it happens every time you drive your car on the highway. When you take it in for your next appointment, get one of their service techs to ride with you. Take the car out on the highway and show him what you're talking about. If, for some reason, you don't hear the noise, put him in the back seat. It might be possible that the weight in the passenger's seat might have some effect on the noise.
Noises like that can be really hard to pinpoint. I had one once which I was convinced was coming from the foot well in front of the passenger's seat. My roommate rode along with me and was convinced it was coming from in front of the driver's seat. After a lot of frustration and experimentation, we finally discovered that the noise was coming from the middle of the car. It was in the spring button on the emergency brake handle.
Have the tech ride along with you, and you should be able to reproduce the noise so he can hear it. Good luck.
Hello, all. I am hoping someone, somewhere can give me some pointers or suggestions. I purchased my 2017 FFH SE last October. Starting around January 2017 my car has made the most annoying rattling sound in the front right corner of the car. I should also mention that when it started nothing out of the ordinary happened to the car...nothing was ran over...nothing damaged...etc. To me (and ever been in the car...other than Ford) it sounds like it is coming from the front right lower exterior of the car. It can only be heard driving on the highway at speeds of 60+. The noise does not change sound or speed the faster you go. It almost sounds like a pop can rattling against metal in the passenger door but it definitely is not. I have checked absolutely everything I can think of. It has been to two different Ford dealers a total of 7 times (most of the seven times it was there for a week or longer) and they claim they can not replicate the noise ()...which I find sooooo hard to believe as it happens every. single. time. I am in the car on the highway. I have even showed them video I have taken of the car making the noise. I am about to be making yet another appointment at yet another Ford dealership soon in hopes that this will soon get resolved before it drives me insane. Thanks in advance for any help!
I have a 2006 SE 3.0 L V6... My issues started with an odd sputter while in park. Things got worse on the way home and the check engine light came on (wouldn't go above 40, shaking, etc...). The codes read multiple misfires on 4,5,6. We were told it was probably the PCM (apparently this model is notorious for PCM issues) so we took it to a shop and after 3 months of them working on it we called and they told us there was nothing wrong with the PCM and we should come pick it up, Also, the coils were not wet or dirty and seemed to have no cracking when we checked them. After putting the PCM back on, we started it to see if anything might have changed. At this point the check engine light was no longer on but the problems were still there. We also noticed that there was a loud knocking in the left side of the intake manifold. It sounded like something was loose. We removed the intake manifold and you could hear something rattle around that my husband could barely feel with his finger. The gaskets seemed in great condition. So......... I am having problems finding any information about that specific intake manifold and/or schematics for it (to try and figure out what was rattling). We are just trying to figure things out and would appreciate any and all info to help with any of the issues. My husband says I need more help than that LOL. We are just ready to pull our hair out and if money wasn't an issues, we would just bring it to the shop. THANKS!!!!