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

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.

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)

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).

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

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

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.

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.

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):

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.