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well we just got back from the dealership road test. The dealership borrowed rims and tires off of a brand new 2010 fusion and put them on for us to drive. THe sounds was not there. So it looks like we have it narrowed down to the rim/tire. What is scary is that we put two different sets of brand new firestone tires on our rims and they both have the road noise. THese were totally different firestone tire types/models/different tread pattern, etc. We will stick with the fr710 firestones and hope they quiet down after a couple thousand miles. I might also go around the car swap each tire/rim combo with the spare and take a test drive to see if it is one specific rim that is causing it. hmmm.......

I can only answer a couple of these questions right now because we dropped the Fusion off at the dealership last night and they still have it to prep for today's big road test. The tires that the Firestone dealer originally put on were Firestone FR710 in the factory size (I double checked at the time) My wife has the SEL package with what looked like lower profile tires that regular Fusions. They were 17 inch. They have been on the car for about three weeks until yesterday when the firestone changed them out for a totally new, higher end set at no cost to us, just to try and fix the problem (we are long time customers). I havent even seen the higher end set yet, since the wife took straight to the Ford dealer after she test drove it and the noise was even worse. We replaced the oem tires at 35K miles due to excessive feathering or wear at the edges of the tires due to alignment out of spec (michigan pot-holes, i think) My wife complained of some noise here and there from either the brakes or the tires but she is fuzzy on if the noise was there before or after the tire swapout. We have not checked the new tire PSI. It has logged about 10 hours at the firestone dealer and an entire week at the Ford dealership for diagnosis, with both places pointing fingers at eachother. I wish I could have just taken it to the dealer, bit the bullet, and spent the big $$$ for factory tire replacements now, but it is too late I think. Thanks for any help. I will update later after the dealership road test this morning. They are taking wheels and tires off of a new Fusion and putting them on our car.

Yes, these had the original Michelin pilot h-something on them from the factory. Very nice tires. I was very upset when I realized that they were trashed at 35k miles due to alignment. I will update this thread for all to see with my ongoing quest to get this resolved.

We had a problem with our 2007 FWD Fusion SEL that the alignment was so out of whack, that it feathered the tires without us noticing, so we replaced the tires at a firestone. There was always some tire noise, but now we have major tire noise. Took car back to firestone, they take tires off and say bearings are bad, take to dealer. We take to dealer and dealer replaces both front bearings, half shaft and cv boot, says the noise is the tires fault. Take back to firestone, the take the tires off and put totally different higher end tires on. Noise is still there, even worse now. We dropped the fusion back off at the dealership tonight and they are actually putting other Fusion tires and rims on it from a new fusion for us to test ride tomorrow. WE literally only have 200 miles left on out warrranty so I hope this fixes it. Has anybody else seen excessive "tire noise" with the FWD Fusion SEL? the noise starts to get loud at 40mph. sounds like we are driving a lifted 4x4 with mudder/off road only tires on it. Yeah, its that bad. Wife isn't happy. She want her old car back. Thanks for any help and advice.