2012 Ford Fusion "Growling Noise"

[nygbrad]

That's funny Phillip. I also noticed a drop in my mpg since the recall / reprogram I had done a couple weeks ago.

[MTLFusion2010]

Not a solution, but I found what I think is a multiplying factor. I recently checked on my air filter and was surprised to see that the third air filter cover clamp (the one closer to the engine) was barely latched. On closer inspection, I found that the air filter cover was not properly seated (the tabs on the opposite side were nut latched to their respective notches in the air-box base.

When I replaced the filter I made sure the cover sat properly (I have to admit this design is not the most friendly one, as I had to muscle the cover into position). Once done all three clamps locked with a positive click.

As I drove the car, I noticed that the growling was almost missing. I paid more attention, and could still detect it but it was faint and hardly noticeable.

My theory is that there is definitely something that vibrates under certain engine loads (could be the issue addressed by TSB 11-10-26 for the Escape/Mariner). However, when the air-box cover is not properly seated, it also vibrates at this frequency. Recall that there is a large resonator box underneath the filter's air-box, which I believe amplifies the sound.

Due to the design of the air-box/cover, it is really difficult to get a good fit, and I assume mechanics under the clock do not spend the time to ensure it is seated properly when changing the air filter..

[DuratorqSupporter]

Sounds like a bogging engine to me, the engine is in too high a gear to really keep acceleration going but the TCM wants the engine at as low of an rpm as possible for fuel economy purposes. If there was a baffle or something loose, it wouldn't go away at a higher rpm, and if the resonance argument was correct you would be able to replicate this scenario every time the engine was turning 1500 rpm, not just when you put the engine under load at this rpm.

 

I don't think anything is wrong, especially since I noticed it in my 2016 Fusion S on my 4th or 5th drive after the purchase.

[kafox]

I have this exact same problem on my 2012 Fusion SEL 4 cyl. I took it to the dealership and they told me they have no idea whats wrong with it.

 

Did anyone ever find a real solution to this? Thanks.

Edited April 9, 2016 by kafox

[davidm]

I had the same problem on my 2012 Fusion SE, 2.5L. My Ford dealer tried replacing heat shields and new exhaust parts but did not solve the growling noise. After I saw the previous post about the 2009-2012 Escape and Mariner TSB 11-10-26, I was able to talk my Ford dealer service manager into installing the Generator Pulley Kit that the TSB references. The repair was made on 11-14-2014. This took care of my problem, no more growling noise.

[kafox]

I had the same problem on my 2012 Fusion SE, 2.5L. My Ford dealer tried replacing heat shields and new exhaust parts but did not solve the growling noise. After I saw the previous post about the 2009-2012 Escape and Mariner TSB 11-10-26, I was able to talk my Ford dealer service manager into installing the Generator Pulley Kit that the TSB references. The repair was made on 11-14-2014. This took care of my problem, no more growling noise.

Thanks! I would like to ask mine to do that but they haven't been very willing to help and would probably charge me tons of diagnostic fees and not actually fix it. Did they charge you for this install?

[davidm]

Thanks! I would like to ask mine to do that but they haven't been very willing to help and would probably charge me tons of diagnostic fees and not actually fix it. Did they charge you for this install?

 

There was no charge. My Fusion was still under the 3 yr warranty at the time.

[kafox]

 

There was no charge. My Fusion was still under the 3 yr warranty at the time.

Ah ok, my car is out of warranty so they will probably charge a ton for parts and labor. If they would even agree to do it.

[Subcooled81]

I have sort of the same sound.

[kafox]

How did you all convince your dealerships to install the parts from TSB 11-10-26? Two different ones have told me no and one of them even charged me a $50 diagnostic fee but still wouldn't do it.

[pfofit]

The net does not show any pics that I can find for part # AL8Z-10344-A from the TSB

The cost is from $125 to $199. seems steep for a pulley. Unless it's a dampener pulley.

 

Anybody have any idea what this "generator pulley kit" consists of and what is involved to install it?

Alternator pulley, idler pulley"s", belt etc.????

Edited September 30, 2016 by pfofit

[ArcaDave]

Hi all, Dave here.  I just about 2 weeks ago purchased a 2011 Fusion with the 2.5  4 cyl engine.  It has 145,000 ish on her and this was one of the first things I noticed upon the test drive.  I also noticed the very micro second noise at initial start up and not being an expert, and just throwing my 2 cents in there, it sounds like the engine is lugging like some folks had previously mentioned.  If you bump the throttle, it down shifts and the lugging goes away.  I am way out of warranty and just know that the stealership would love to take me to the cleaners on it, so if you drive it like a 4 cylinder and not a hot rod, it should be fine.  Correct me if I am wrong or am way out there on this.  I love the car and the first few days, it also gave me the dreaded check engine light.  It turned out to be the little 2 bolt evap purge valve on the front of the engine that everyone seems to have to replace at one point or another.  I changed the part and no more engine light.  Take care all..Dave in Charleston.

[eGuru]

Replacing the belt tensioner should resolve the rumble.

[ken123]

No it will not. Had mine replaced twice, noise and vibration still there at 1500 RPM with AC on.

[davidm]

Did they replace the pulley with the Pulley Kit, Ford part # AL8Z-10344-A, referenced in 2009-2012 Escape and Mariner TSB 11-10-26?  This Pulley Kit took care of the growling noise on my 2012 Fusion and also my sister's 2012 Fusion, both with the 2.5L 4 cylinder  motor.

[eGuru]

10 hours ago, davidm said:

Did they replace the pulley with the Pulley Kit, Ford part # AL8Z-10344-A, referenced in 2009-2012 Escape and Mariner TSB 11-10-26?  This Pulley Kit took care of the growling noise on my 2012 Fusion and also my sister's 2012 Fusion, both with the 2.5L 4 cylinder  motor.

davidm,

 

What did the AL8Z-10344-A kit include?

Was it the belt tensioner and the alternator clutch pulley?

 

The "kit" sells for a ridiculous price, is hard to find, and I can't find out what is actually in it.

I'm sure that we could find the individual components for much less if we shop around so please tell us what you know.

 

[davidm]

eGuru.

 

Evidently the kit is just a pulley per description on FordPart.com below:

PULLEY
Part #: AL8Z10344A
Pack Qty: 1           Price:  $ 185.53

 

That was the part number on my repair order for my 2012 Fusion. I did not look at the part but I would think it was the tensioner pulley with stronger tension to stop the harmonic oscillations that are causing the growling sounds. Have you tried checking to see if an aftermarket parts store can cross the part number over to something they have?

 

 Good luck,

[eGuru]

15 minutes ago, davidm said:

eGuru.

 

Evidently the kit is just a pulley per description on FordPart.com below:

PULLEY
Part #: AL8Z10344A
Pack Qty: 1           Price:  $ 185.53

 

That was the part number on my repair order for my 2012 Fusion. I did not look at the part but I would think it was the tensioner pulley with stronger tension to stop the harmonic oscillations that are causing the growling sounds. Have you tried checking to see if an aftermarket parts store can cross the part number over to something they have?

 

 Good luck,

davidm,

 

Thanks for the response and the suggestion to check with an aftermarket parts store to see if they can cross-reference the part.

 

I was thinking that it had to be something other than the tensioner since ken123 says that he had his replaced twice and it didn't fix the problem.

Also, in the TSB11-20-26 they reference "install alternator pulley kit" so I was thinking that's what it likely was

 

I guess more investigation is required.

 

Thanks for the help.

 

[ken123]

This link explains how it works

GATES TRAINING: Comparing Solid OWC & Pulleys - YouTube

[sirtanon]

23 hours ago, davidm said:

eGuru.

 

Evidently the kit is just a pulley per description on FordPart.com below:

PULLEY
Part #: AL8Z10344A
Pack Qty: 1           Price:  $ 185.53

 

That was the part number on my repair order for my 2012 Fusion. I did not look at the part but I would think it was the tensioner pulley with stronger tension to stop the harmonic oscillations that are causing the growling sounds. Have you tried checking to see if an aftermarket parts store can cross the part number over to something they have?

 

 Good luck,

 

Even cheaper if you check around:

 

https://www.fordpartsgiant.com/parts/ford-pulley_al8z-10344-a.html

- Only $120

 

Amazon:

https://www.amazon.com/Ford-AL8Z10344A-Pulley/dp/B01FL4BOX6/ref=sr_1_1?ie=UTF8&qid=1505945088&sr=8-1&keywords=AL8Z10344A

- $100

[eGuru]

8 hours ago, ken123 said:

This link explains how it works

GATES TRAINING: Comparing Solid OWC & Pulleys - YouTube

 

Are you thinking that the part in the kit is an Overrunning Alternator Decoupler (OAD)?

 

Possibly from Likens?

[eGuru]

1 hour ago, sirtanon said:

 

Even cheaper if you check around:

 

https://www.fordpartsgiant.com/parts/ford-pulley_al8z-10344-a.html

- Only $120

 

Amazon:

https://www.amazon.com/Ford-AL8Z10344A-Pulley/dp/B01FL4BOX6/ref=sr_1_1?ie=UTF8&qid=1505945088&sr=8-1&keywords=AL8Z10344A

- $100

 

sirtanon, thanks for finding those less expensive suppliers.

 

I'll see if I can find a local source also as Amazon is not an available choice in my region.

Also not sure if I want to go through the pain of replacing an alternator pulley or just live with the occasional rumble.

 

Thanks for your help

 

 

 

[davidm]

I think the Gates Training video is spot on with the replacement pulley.

[badassabe]

Any Happy endings to this problem on the Ford fusions? I believe I have the same issue too

[CurlyFresh]

On 7/6/2013 at 3:50 PM, ken123 said:

Still trying to track down this noise, removed the belly pan and drove it, noise is still there.Infant in a previous post had a mech. check his out and said the ac compressor was the problem, I don't think it is.

It has something to do with a harmonic vibration with the belt that drives everything and the ac compressor load just makes it worse.

This is my opinion from trying everything else.

It seems that there is a TSB out on the Escape/Mariner with the same engine for this problem, something about a revised alternator pulley, why

not for the Fusion?

 

On my 2011 Fusion SEL 2.5L with 143K I have recently begun to notice this same issue. I also noticed with the arctic blast last week that the engine pulleys did seem to make sound noisy and different, That's when I first noticed the growling. I suspect the engine may indeed be under more stress, but due to the pulley needing replacement as I think it/they may not be as free spinning as they once were. will report back when I have hard information.