15 AWD Fusion Shuddering during low speed turns

[Boss7t]

I have a 2015 AWD Fusion that shudders/vibrates during low speed turns. There are no codes or lights illuminated. This vehicle is not under warranty so I'd like to fix it myself. Troubleshooting by process of elimination seems to indicate the viscous coupler. Has anyone performed the diagnostic steps and/or replacement procedure for it? 

[Waldo]

The Fusion doesn't have a viscous coupler, it has an RDU with an electronically controlled dry clutch.  If the clutches are locked on, then you would get the shuddering.  Try disconnecting the electrical connector going in to it.  That should open the clutches permanently.  If you still have the shudder after that, then either the clutches are mechanically locked, or the problem is something else.

[Boss7t]

Thanks for the advice. I disconnected the connector and it drove normally - with the exception of the  AWD system warnings of course. 

[Arlenok]

Hi there, I know this is an older post but did you happen to fix this issue?

[Boss7t]

Yes. It was the viscous coupler in the rear diff. Part

CV6Z-4A232-A.

[Arlenok]

Thank you for the response! So was Waldo incorrect in saying that the Fusion doesn't have a viscous coupler?

 

I searched for that part but it looks like it is for a Ford Edge, can't find it anywhere that shows compatibility with a Fusion.

[Boss7t]

That’s the part number I ordered and installed  from the ford dealer. The description from the invoice was a viscous coupler.

[Arlenok]

Fair enough, I can't argue with that. Thanks again for responding, I'm having the same issue with a 2017 Fusion Sport. I'm not sure if we share the same RDU but this is the best answer I've seen so far, I can't find any info on this specific shudder anywhere else.

[Boss7t]

I couldn’t find anything either. Waldo’s suggestion of unplugging the unit was what ultimately led to identifying the problem. Good luck!

[Waldo]

Ford used the same RDU on just about everything in that era, Edge, Fusion, Explorer, Flex and all the Lincoln products.  The first generation of that part (Ford Five Hundred, first gen Edge and so on) was a wet clutch (so the viscous couple definition fit), but at some point it evolved into a dry clutch system, so technically it's not a viscous coupler anymore, but I'm sure they didn't update the parts catalogue.  But it doesn't really matter, as long as you're getting the right part.

 

It's pretty rare to find people reporting failures with the RDU though, especially considering how common it is on other Ford vehicles.  I wonder if there's something a little unique about the Fusion that causes issues.

[Arlenok]

I'm really not sure what's going on either, but apparently there's a service bulletin on this that affects basically every car with this RDU, and shows exactly the part number Boss7t mentioned... The service bulletin is as follows, posting it here in case it helps anyone else in the future.

 

 

SSM 46965 - 2013-2018 Various Vehicles - Rear Axle Noise – Low Speed Parking Lot Maneuvers – After Extended Driving

Some 2013-2018 Escape/EcoSport/Edge/MKX/MKC/MKT/Fusion/Flex/Kuga/Mondeo all-wheel drive (AWD) vehicles may exhibit a clunk, thump, grinding, popping, shuddering or chattering from the rear axle when the vehicle is turning during parking lot or figure 8 maneuvers at low speed after extended driving. Replace the RDU clutch using service kit CV6Z-4A232-A. The Workshop Manual (WSM), Section 205-02 has been updated to include this repair. For claiming, use causal part 4A232 and applicable labor operations in Section 04 of the service labor time standards (SLTS) manual. 

APPLICABLE VEHICLES
 2014 - 2018 CAR: ED CD539A EDGE
 2016 CAR: ED CD539A EDGE
 2016 CAR: ED CD539A EDGE
 2015 - 2018 CAR: DQ CD539N EDGE
 2016 - 2018 CAR: DQ CD539N EDGE
 2013 - 2018 TRUCK: M2 C520N ESCAPE
 2013 TRUCK: M8 ESCAPE/TRIBUTE (J87)
 2013 - 2018 CAR: C7 CD391N FUSION
 2013 - 2018 TRUCK: P3 D471N FLEX
 2015 - 2018 TRUCK: ME C489N MKC
 2013 - 2018 TRUCK: P4 D472N MKT
 2013 - 2015 TRUCK: Q1 U387/388N EDGE/MKX
 2016 - 2018 CAR: D9 U540N MKX
 2013 - 2018 CAR: C9 CD533N MKZ
 2013 - 2018 CAR: BQ B515S ECOSPORT
 2017 CAR: BX B515A ECOSPORT CHINA
 2017 - 2018 CAR: BW B515A ECOSPORT INDIA
 2014 - 2018 CAR: R1 B515E ECOSPORT RUSSIA
 2013 - 2014 CAR: BV C394 EU KUGA - C1 CAR
 2013 CAR: BV C394 EU KUGA - C1 CAR
 2013 - 2018 CAR: BS C520 FOE
 2013 - 2018 CAR: BS C520 FOE
 2013 - 2018 CAR: CK C520A KUGA CHINA
 2013 - 2017 CAR: CZ C520A KUGA TAIWAN
 2015 - 2018 CAR: NG CD391E MONDEO
 2015 - 2018 CAR: NG CD391E MONDEO 

 

[notamechanic44]

I know this thread is dead, but wanted to give my experience with the viscous coupler on my 2015 ford fusion 2.0 AWD with 140,000 miles. I scoured the internet on this topic and came up short except for this thread. Hopefully this post will help someone in the future.  One day I was turning out of the grocery store and I thought someone had hit me. I pulled over to check the car and everything seemed fine. I continued on my journey home, but every time I turned at low speed the back end would shudder or the rear tires would chirp. I unplugged the sensor and everything seemed to work fine, minus the AWD warning light.  I came across this thread and saw the bulletin from Ford on the viscous coupler. The only thing was when I looked part number CV6Z-4A232-A in google the ford fusion was not in the list of vehicles. I decide to continue on with the teardown, because from what I saw on the internet looked a lot like the rear end on my car. The process took me about 5 days to take the part out due to not having much guidance and working on the car at night after work. Here are the steps I took to remove the viscous coupler in my car. 

 

1. There are 6 torx 45 bolts that you need to remove from the rear driveshaft. I considered these bolts to be a one time use, because half of them were on the verge of stripping. 

2.There are 4 torx 40 bolts on the viscous coupler housing you will need to remove

3. You will need to remove the two 13mm bolts that hold the center drive shaft bearing. This will allow you to move the drive shaft away from the viscous coupler housing.

4. There will be plate that holds the grease for the rear driveshaft connection in the coupler housing. This part will need to be removed with some plyers to be able to access the last bolt holding the housing on. 

5. The bolt behind the plate is also a 13mm. Once the bolt is removed, then you will have to break the housing free, because the coupler housing is attached to the differential with grey gasket maker. Once you remove the housing, you will have access to the viscous coupler. 

6. Remove the viscous coupler from the vehicle. I had to use a  little bit of force for this step. 

7. There are 4 torx 50 bolts that will need to be removed to separate the front of the viscous coupler and the spindle on the front of the viscous coupler. 

8. You should now have access to the sensor of the viscous coupler. There is a metal ring  in the center that you will need to remove, so you can remove the sensor. 

9.Once the sensor is removed,  there are 3 torx 25 bolts you need to remove. Once these bolts are remove the final piece should slide out.  

10. Take a deep breath, because the viscous coupler is now out of your vehicle. 

11. Order the part and install everything in the reverse order. 

 

When I removed the coupler I notice some of the splines had worn down  just enough to cause some slippage. I paid $462.00 for the viscous coupler part number  CV6Z-4A232-A and 6 driveshaft bolts $1.62 a piece part number 5F9Z-4682-AA. The drive shaft bolts come in pairs of two, so I really only bought 3 pairs. I hope this post provides some guidance to a DIY like myself. 

 

 

 

Edited November 29, 2023 by notamechanic44