awdpath

Another possible source of the front end noise ( "Front suspension noise"):

 

TSB 08-18-4

09/15/08

FRONT STRUT NOISE

 

FORD:

2006-2009 Fusion

LINCOLN:

2006 Zephyr

2007-2009 MKZ

MERCURY:

2006-2009 Milan

ISSUE

Some 2006 Zephyr, 2007-2009 MKZ, 2006-2009 Fusion and Milan vehicles built before 8/5/2008 may exhibit a popping, rubbing, grunting, squeaking, crunching or creaking type noise from the front strut mount when going over bumps, while driving at 1-10 MPH (1-16 Km/h) and/or during parking lot maneuvers. Typically, the noise is heard in the front outboard wheel while turning at low speeds. This noise may be caused by the jounce bumper rubbing against the dry strut plate.

 

ACTION

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

1. Raise the vehicle as described in Workshop Manual (WSM), Section 100-02.

2. Remove front shock absorber and spring assembly per WSM, Section 204-01.

 

3. Disassemble the shock absorber and spring assembly per WSM, Section 204-01 under Disassembly and Assembly section.

 

4. Apply Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound 3600 around the upper and lower contact surfaces of the shock absorber piston bounce bumper. (Figures 1 - 2)

 

5. Repeat the procedure on the other side of the vehicle.

6. Lower the vehicle.

 

Parts Block

 

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

IMPORTANT : Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATION DESCRIPTION TIME

 

081804A 2006-2009 Fusion/Milan, 1.8 Hrs.

 

2006 Zephyr, 2007-2009

MKZ: Apply Lubricant,

Includes Time To

Remove/Install And

Disassemble/Reassemble

Both Front Strut

Assemblies. (Do Not Use

With 18124A, 18124AT)

DEALER CODING

CONDITION

BASIC PART NO. CODE

18198 69

Read the whole thread. The problem was identified over a year ago. It's a result of the rear differential disengaging at the same time the TCC is locking up. This causes the monetary shudder. It's a software issue. I was assured that a report was made to the engineers in Dearborn and that a fix would probably be found but that it would take time b/c any change like this had to be submitted and approved by the EPA. Well, here we are, a year later. Nothing has happened and this story was apparently a steaming pile of BS. If this really was the case, why would Ford continue to spend thousands replacing expensive driveline parts in other customers' cars when they supposedly know what the issue is? Dealers would inform owners that no repairs would be done pending a TSB.

 

...

 

This is simply unacceptable.

 

These types of AWD systems were never designed to be 'disengaged' at driving speed ( maybe when parking or when emergency/parking brakes are engaged). I am not surprised if the disengagement feature was forcefully incorperated into the 3.5L sports model only to make it more appealing for some customers ( like wptski, lol) and possibly EPA requirements to save at most 1 mpg under certain driving conditions.

... The suspension is like most of the rest of late model cars, so stiff that fatter tires can't do much for it. When I go over bad spots, the wheels don't follow the road surface leaving the body level, but the whole car moves up and down....so much for the exotic five link rear suspension. I know I will be hated for saying it, but I can drive my 1971 T-Bird down bad washboard and severe potholed roads at highway speeds that I couldn't go over five or ten miles per hour in my Fusion. As far as the rest of the car is concerned, it's all GREAT!

 

 

Let me guess ... Inland Northwest roads. For recent models, I think you will like the Chrysler Sebring ( the 200 might be too stiff for you!).

The Mondeo's front suspension is of MacPherson strut types. The current "North American" Fusion 's SLA front suspension is technically superior ( and actually more expensive to make!).

What you saw in above video where it shows the underside of the car is what I see under my 2007 Ford Fusion SE AWD. The Fusion I4 models ( current ones as well?) do have a cover like you described.

 

 

Starting at 3:20

Underneath the Fusion V6 (06-09)

 

 

 

I don't think there is a AWD Fusion TSB for oil smell ( the Edge, yes). However, removing the Fusion's V6 oil filter can be quite a mess and may be the source/cause of the oil smell.

Maybe related to this issue:

 

TSB 07-2-1 (Key Stuck in Ignition)

LOL! At least get those tires! It never ceases to amaze me how they do that. Also, what could make a person want to ride shotgun in one of those AND be able to take their eyes off the road to read a map...

 

Very hard:

 

 

 

However, it can be done:

 

Get one of these:

 

Put the car in gear ( D or R). If still not getting power, feather the gas pedal. Try this as a temporary workaround. Possibly a weak battery?

Eagle RS-A tires? Your are a brave man driving those things in the northern winter areas (especially for the sports size).

Update !

 

I took my car to the FORD dealer today. After there inspections it was determined that my drive shaft and carrier bearing is bad. They replaced both free of charge under the drive train warranty i guess since i have passed my 3yr / 36.000 warranty by 1.500 miles. Ford took care of the issue and i must say i was extremely pleased !

 

Not "free of charge" ... your car's 5 years/60,000 miles Powertrain Coverage took care of that.

2009 Fusion 3.0 with automatic climate control. Problem is when idleing there is no heat. When I give the engine some revs it starts to blow heat but when it goes back to idle, the air goes cold again. The coolant tank is full and there are no coolant leaks. What could be the problem?

 

Very likely just need a burp or two then top it off. Car under warranty? Just let the dealer/Ford deal with it if yes.

The supplier’s Ford business includes all major car-based models including the Ford Escape, Edge, Fusion, Flex, and Taurus; Mercury Milan; and Lincoln MKX and MKS. Beginning 2011, it will add the Ford Explorer, which will switch from a truck platform to a front-drive, unibody architecture.

 

Line One is dedicated to Ford, still JTEKT South Carolina’s top customer. Couplings produced on the line are shipped to Dana Holding Corp., which attaches them to the rear differential and then ships the assembly to the auto maker.

 

There are virtually no torque limitations to adapting ITCC to front-drive vehicles, Krupp adds. “Anything from 400 Nm to 2,000 Nm (295-1,475 lb.-ft.) in rear-axle torque can be undertaken.”

 

- JTEKT South Carolina Plant Eyes Post-Recession Rebound , By Roger Schreffler WardsAuto.com, Oct 14, 2009 8:00 AM

I have a 2008 Fusion with 53,000km ( 33,000 mile) equipped with an Aisin transmission and the 3.0L engine which refuses to shift into a higher gear when the car has 5 people in it goes up moderate hills or when it tries to go up a steep hill from a standing stop. Engine revs to 4500 before I can remove my foot from accelerator. Very disconcerting and a little scary

Valve body was replaced as per TSB 08 24 01 and calibration rechecked. No change to condition. Service manager says all Fusions of that year and similarly equipped experience that problem. That's little consolation

 

I think under certain conditions ( heat and/or load?), the transmission automatically goes into "L" mode.

Hey...im new to the forum. I bought a used 2009 Fusion SEL V6 with the sports package and a white exterior/black interior almost 2 months ago. I got it with about 26,000 miles on it. So far i love it. I look forward to conversing about the fusion with other members here. This seems like a good forum to discuss the car and learn about problems people encounter with it.

 

Unfortunately, not much to learn here that applies to the 2009 models.

Is it more pronounced when accelerating out of turns?

Haldex to divest Traction Systems Division to BorgWarner, Inc.

Today I was driving in the snow when and idiot light came on,it was the one that looks like a little wrench on the left side of the dash,the manual said it was a AWD malfunction and to get the car to a dealer immediately -the car started shifting badly and hesitating. So I puled over and shut it down for a minute, then i restarted and the light was out and the car felt fine, Does anyone know if this is serious or just a little glitch? should I go to the dealer? Thanks

 

Anything that was plugged into the OBDII connector or the 12V accessory socket ? Something might of interfered with the communication system. A scanner should give you a code or two.

Tried No Touch GS8 Auto Glass Stripper?

 

It appears to have 'Cerium Oxide' in the mixture.

 

So I have a 07 ford fusion V6 that has 63K miles. I've never had the transmission fluid changed and I was looking in the maintenance manual and it says it needs to be changed every 30K miles. So I'm considering getting the transmission fluid changed but I've heard it may due more harm than good to have it changed in vehicles that haven't been routinely changing it. What is your opinion on having the fluid changed now? Is it too late or will it do some good? Also lately my car has been shifting harder and I didn't know if changing the transmission fluid would help. Any help would be appreciated, I don't know too much about cars.

 

Thanks

 

Only under " Special Operating Conditions."

See..

 

TSB 08-24-1 (Harsh Shifting Above 20,000 miles)

 

And Ford did not recommend 30k tranny flush unless your car falls under 'Special Operating Conditions'. ( for 'normal' operating conditions ... about 150k or more!)

Fiber optic LED strip ( the best looking ones by far):

 

 

I think that it showed side to side but that can't be proven because Ford killed the link. Even back to front doesn't happen either. You have SG-II, so if you can find a proper road to test it on. You haven't tried a heavy throttle from a dead stop either or just don't want to say so?

 

What the '07 Workshop Manual stated, I posted above. Yes, it states that it has a heat protection mode but there is only one cable going to the ATC which is the one that operates it. Nothing in the electrical showing a temperature sensor only the two wire cable that operates the ATC.

 

Waldo says that it's in my owner's manual, it's not so I ask you also, what page in your owner's manual describes a dash warning about heat protection as I'd like to read that??

 

If the winding road scenario is shown with wheel/s losing traction, then yes, Ford can illustrate side to side and front to rear torque vectoring simultaneously as well.

 

The ATC ( Active Torque Control Coupling Solenoid ) is installed as an assembly with the rear axle by Dana Holding Corporation (2007-2009). It is a seal for life and an assembly replacement component.

Look under Maintenance and Specifications > Refill Capacities in the 2006 Owners Manual.