Took to dealer under warranty to investigate the blower motor humming and getting louder with each setting from 3 to 7. Even the service writer said "that would drive me nuts."
From phone call it sounds like they are not going to replace it under warranty. Word is something to the effect I must have done something to it, because blower motors "don't wear out in Fusions." Of course they don't. I did change the cabin air filter - even used Motorcraft. "Well that's probably it then, most likely something dropped down into the motor and that won't be covered under warranty, blah blah."
I told him he was probably too young to remember the days when there were these things called sealed bearings. "I know ALL about sealed bearings, blah, blah." Sure you do, you wrote your doctorate in mechanical engineering on sealed bearings. Which is why you're a service writer at a Ford dealership.
I see a blower motor for $110 on AutoZone web site. I may just have to bite the bullet and change it myself.
Although I do have the luxury of trying a few more Ford dealers in the Dallas - Fort Worth area before going that route.
So the real question since "Fusion blower motors do NOT wear out": Anyone ever replace one? I assume you did just for fun since they "don't wear out."