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Got my car back. New rear end, new rear driveshaft, new torque converter. From the small amount of driving I did on the way home from the dealer, it appears the problem may be gone. I do not know though, so I will continue to look/listen for the rumble. Now I just need to get rid of the thing before it breaks again

those tail lights look sweet. did you darken them somehow or is that just lighting?

just wondering if the Traction control is turned off, will that save any MPG on dry pavement?

no, that is what they are doing. Sorry, I guess I wasn't clear in my post, that they are replacing the whole rear end.

the dealer seems pretty confident that this will fix the problem. only time will tell i suppose..

Update #2: Dealer had my vehicle for a week. The tech working on it was in school (I hope FORD school and not some high school kid doing my work ) which is why it took longer. The svc mgr said a new rear driveshaft was installed and the problem persisted, so the next test in line that Ford had them do was "unplug the rear axle". (SHEESH these new cars have a ton of electronics. Lot different than my 89 k-1500 that I just got rid of). I don't even know what unplugging the rear axle does but regardless, doing that made the noise go away (or so they say.. time will tell). So, they are giving me back the car to use while they order a new rear axle. I would have thought that those axles are like a CV, no? I know i dont have a Dana 60 under there :hysterical2: but regardless, they are now changing the rear axle hoping that will work. I will post back when I take it in again, probably should be taking the car back in sometime mid next week.

thanks, I have read the whole thread and saw that it was basically a software error. I will wait and see what Ford wants to do with it. The tranny flush was suggested since i have 35K miles on it, and I noticed on the service ticket (mostly in dealer jargon) that it said 8 qt ATF, so I figured I got some new fluid. It was unrelated to the problems I'm experiencing. Has it been determined that this wont cause any "harm" to the vehicle and its just an annoyance? If so, I can live with it, but I don't want to wear out a rear differential come 60,100 miles

The highest I've gotten has been 23.3-ish, and that was on a trip to Columbus from Pittsburgh (200 miles) I usually average about 22.5 to/from work, a 55 mile mostly highway commute.

I am having this problem as well on my 2010 Fusion Sport AWD. Took it to the dealer and they told me it was a bad torque converter. I figured they would be wrong, but I also had a different vibration about 60MPH so I let them fix that and it got rid of that one. I still have the one at 40MPH under light acceleration. They took my Fusion back yesterday and the technician said he thought it was driveline related and wanted to see what Ford would say to do, as they had never experienced this at the dealer before. (I wanted to tell them to come to this site, but I figured I'd let them call Ford first. ) So I will be checking back, but it appears I got a new transmission the first time (is the TC and transmission one piece?) The service manager suggested i get a tranny fluid flush but I think that would be pointless w/ a new tranny. Also, they aligned it for me, because the "subframe had to be disassembled", which was kind of nice as I needed an alignment anyways, and it saved me $40. Now I will wait to see what I hear from them.