sleepysam22 Posted October 17, 2021 Share Posted October 17, 2021 Well folks here I go again. Started car and turned on ac to have white particles blowing out the vents and covering me in white powder like material. Took vehicle to dealer and was told the flux on the evaporator is most likely flaking off again and they will need to pull the dash again to inspect the evaporator and box. Advised dealer I am declining repair. Took vehicle to sales department and traded in the vehicle. It can now be the dealers problem as there is no way this vehicle will be sold if a customer is smart enough to turn on the ax or heat. 2019 fusion owners be prepared to have a full dash removal should you notice this on your car. I want to thank you all for all of your help over the last couple years as I will no longer need this awesome forum. Take care all 0 Quote Link to comment Share on other sites More sharing options...
bbf2530 Posted October 17, 2021 Share Posted October 17, 2021 3 hours ago, sleepysam22 said: Well folks here I go again. Started car and turned on ac to have white particles blowing out the vents and covering me in white powder like material. Took vehicle to dealer and was told the flux on the evaporator is most likely flaking off again and they will need to pull the dash again to inspect the evaporator and box. Advised dealer I am declining repair. Took vehicle to sales department and traded in the vehicle. It can now be the dealers problem as there is no way this vehicle will be sold if a customer is smart enough to turn on the ax or heat. 2019 fusion owners be prepared to have a full dash removal should you notice this on your car. I want to thank you all for all of your help over the last couple years as I will no longer need this awesome forum. Take care all Hi sleepy. Sorry to hear you had issues with your Fusion. Was your 2019 Fusion outside the 3 year/36,000 mile New Vehicle Warranty? Either way, good luck. 0 Quote Link to comment Share on other sites More sharing options...
Fusor Posted November 20, 2023 Share Posted November 20, 2023 Absolute yikes. I'm dealing with this exact same issue -- blowing caustic aluminum salt particles all over my eyes and face (it burns!) when I try to use the vehicle, and it still manages to come through even if I turn the climate control off. The vehicle is basically unusable in this state. Anyone have a better solution than selling the car and giving up? I actually rather like this car, and this is the only issue I've had with it so far (101,000 miles). Ford wants $3,200 which is pretty much out of the question. Should I try using an aftermarket brand of evaporator core that doesn't have this alleged known factory defect? I was also thinking about the fact that these are electrically driven compressors, I wonder if the voltage is leaking through the A/C components, causing this premature corrosion? If this is the causative factor, I believe this problem could be eliminated with a well placed ground strap. I've also heard that I may be able to join a class action lawsuit over these premature evaporator failures, as they have been occurring very frequently on similar year Ford vehicles. Would love to hear everyone's thoughts and opinions. 0 Quote Link to comment Share on other sites More sharing options...
drolds1 Posted November 20, 2023 Share Posted November 20, 2023 Unless your car is a Hybrid, the AC compressor is belt-driven, not electric. 0 Quote Link to comment Share on other sites More sharing options...
Fusor Posted November 26, 2023 Share Posted November 26, 2023 Yes, mine is PHEV. It does look like this failure is occurring in both hybrid and non-hybrid vehicles, so I don't think it's related to the electrically driven compressor. I hate to say it, but a defective evaporator from the factory seems to be the most likely cause. This is just crazy. I've owned several Fords over the years, and drove them all to 150,000+ miles without any major issues. Never had to deal with evaporator defect issues like this in my previous Ford vehicles. 0 Quote Link to comment Share on other sites More sharing options...
drolds1 Posted November 26, 2023 Share Posted November 26, 2023 Interesting. I found a Ford TSB from 2002 describing this problem: Quote ISSUE: Some vehicles may exhibit white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by excessive amounts of brazing flux utilized in the manufacturing process of the evaporator. ACTION: Using compressed air (90-150psi), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. Refer to the following Service Procedure for details. 0 Quote Link to comment Share on other sites More sharing options...
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