Old thread, but related to my topic. While I was on a trip to Denver, the car developed an annoying rattling noise from the lower passenger door area. It sounded like two thin pieces of metal rattling, so I thought it was a part of the window mechanism. I noticed that it only rattled at certain speeds and was a constant sound regardless of bumps or speed. I shook the door and didn't hear anything, then I started looking for loose rubber seals, molding and body parts around and under the car. As I was walking to my car the other day, I noticed the plastic inner wheel well liner was slightly separated from the edge of the body and the plastic plug had come out slightly. I pushed the plug back in and it seems to have solved the problem. How it wiggled out is a mystery, we had a lot of rain and I drove on the interstate in a heavy rain storm, so water may have got behind the liner, but problem solved and partial sanity restored.
Well, the noise is back at speeds over 65-70 mph, which make me believe it's something under the car, or a panel. I'm taking it in next week.
I have experienced a squeaky noise coming from the lower passenger door. I have tried to press down on bunch of parts to see where the noise comes from. It seems pressing down on the shiny plastic panel that holds the window buttons helped. Nothing seems to loose.
In general, I feel the car interior just rattles a lot, even compared to the old Pontiac Grand Prix I have. I don't know if it is a general problem with Ford Fusion or I just have a bad one.
Other than the rattle that appeared after 10,000 miles, my Fusion has been rattle free and a very quiet ride. There's always a chance you got a car that a screw or two wasn't tightened to spec, but I don't think Fusions are any more prone to rattles than any other vehicle.