My new Fusion 2012 Sport has rattling issue. I only have 400 miles on it and it drives me crazy. It occurs while driving 40mph to 65mph on a concrete highway. Somehow the asphalt doesn't cause the rattle to occur. I tried to bang the seat, tap the passenger side post, played with the seat seatbelts, inspected the glove box, looked under the seats, tapped the cup holder area, checked the sun visors pretty much anything I can think of and the rattle won't go away. It's rattling at me like a rattle snake and I hate it, because I can't even tell where exactly it's coming from! All I know it sounds like to pieces of cheap plastic rubbing or possibly a loose wire? All that for $35 000. Shame on Ford not being able to build solid cars.
My 2007 Fusion SE is built so robustly, that I wonder that lot of Fusions were better made before the economic crisis. When I look at the details in the those two cars I see that the new Fusion is cheaply made :-(
Gas pedal feels mushy and steering is too light to compare with my 2007 Fusion which has 60 000 miles on it!