2010 Fusion Sport 3.5L AWD

[amfinance]

I would have to say,too, that it is VERY ODD, to have the same problems with different powertrains, but I was intrigued that the 3.5 had the same problems as the others ( 2.5 & 3.0 ) that I had.

 

Maybe the issue isn't powertrain...... Maybe it's the car itself...........Maybe aerodynamics??? Maybe wheel bearings??

I'll find out as my car (3.0) is at the dealer now..... The service manager said they had some complaints of the same problem with ALL (2.5, 3.0, 3.5, fwd, awd ) but could not replicate the problem.

drold-any word from your FSE when a potential fix might be coming? i am watching for updates before I bother re-visiting the dealer

 

thx

[juice]

drold-any word from your FSE when a potential fix might be coming? i am watching for updates before I bother re-visiting the dealer

 

thx

 

IS THERE ANYBODY OUT THERE THAT GOT THE VIBRATION FIXED YET....JUST WONDERING WHAT THE CAUSE WAS

[drolds1]

IS THERE ANYBODY OUT THERE THAT GOT THE VIBRATION FIXED YET....JUST WONDERING WHAT THE CAUSE WAS

 

Still waiting. I was planning on giving them a call shortly.

[jpp747]

IS THERE ANYBODY OUT THERE THAT GOT THE VIBRATION FIXED YET....JUST WONDERING WHAT THE CAUSE WAS

I have the same problem with my 08 MKZ going thru that range, in acceleration or costing down. The drive shaft was replaced with a 90% improvement. 10 month latter the center support bearing let go with a high pitch noise. Drive shaft was changed again. 2 days after I’ve noticed the same rubble and vibration going thru 50 to 60 mph. Toke it back to the dealer and after 2 days of test they came with the conclusion that the drive shaft was the cause of the rubble. They drove the car without the drive shaft and the car was just like a fwd .No rubble or vibration. After they have contacted Ford Tech Support, they were told that Ford had a new type of drive shaft available for that chronic problem and it would take 10 to 15 days to get it .May be you should get a test drive without the drive shaft. It worked for me, so far. Will let you when the new drive shaft is install.

[drolds1]

I have the same problem with my 08 MKZ going thru that range, in acceleration or costing down. The drive shaft was replaced with a 90% improvement. 10 month latter the center support bearing let go with a high pitch noise. Drive shaft was changed again. 2 days after I’ve noticed the same rubble and vibration going thru 50 to 60 mph. Toke it back to the dealer and after 2 days of test they came with the conclusion that the drive shaft was the cause of the rubble. They drove the car without the drive shaft and the car was just like a fwd .No rubble or vibration. After they have contacted Ford Tech Support, they were told that Ford had a new type of drive shaft available for that chronic problem and it would take 10 to 15 days to get it .May be you should get a test drive without the drive shaft. It worked for me, so far. Will let you when the new drive shaft is install.

 

Your problem, as you described it, is nothing like the problem described in this thread. You said that your rumble " is going thru 50 to 60mph." If you read the postings here, you will note that the issue is a rumble at 40mph/1500rpm that lasts only briefly. In other words, it's gone at 41mph or any engine speed above 1500rpm.

 

Thanks for your input, but these are two entirely different sets of circumstances.

 

 

BTW, I recently contacted my dealer and there's nothing going on with this. They're going to get in touch with the FSE. All indications are that this isn't going to solved anytime soon. I'll be quite surprised if anything develops. If it does, I'll be sure to post it here.

[apollo8801]

I just came back from my local dealership 5 hours ago and the shop foreman drove my car and he heard the noise and he had a client with the same issue some months ago and after 30 + hours working on the other car and some driving around with the diagnostic computer it was determined that the noise was the rear end clutch pack disengaging as it does not feather out it just drops it out (not sure the technical term as I am not a gear head) . So that is "normal' he told me to check back in in about 6 months to see if Ford release a update to the computer that controls that.

 

hope this helps

mike

[drolds1]

I just came back from my local dealership 5 hours ago and the shop foreman drove my car and he heard the noise and he had a client with the same issue some months ago and after 30 + hours working on the other car and some driving around with the diagnostic computer it was determined that the noise was the rear end clutch pack disengaging as it does not feather out it just drops it out (not sure the technical term as I am not a gear head) . So that is "normal' he told me to check back in in about 6 months to see if Ford release a update to the computer that controls that.

 

hope this helps

mike

 

Too bad you didn't see my report here before the dealer wasted 30 hours diagnosing it. My car got a new TCM, valve body, torque converter and rear differential, all to no avail. Like you, I'm waiting to hear something from Ford. I'm not holding my breath and you shouldn't either. This started out as no big deal to me, but it's starting to get a little annoying. It may be my imagination, but it seems that I'm feeling it a bit more intensely and it has gotten a little louder lately.

 

The good thing is that the more complaints they get, the more likely they might come up with a fix. Your dealer is correct in that it's a software issue.

 

For the record, they told me I was the first person to complain and they're a Ford-Lincoln-Mercury as well as being one the highest volume dealers in the area. So, they've sold plenty of these. The SM, with whom I have a long-standing relationship, told me he felt it in his personal car also but it didn't bother him. And why not? He gets a new car all the time and his father owns the dealership as well.

Edited September 17, 2010 by drolds1

[packrats]

I have owned a 2010 Sport AWD for a year and almost 12k miles. The rumble condition everyone has been disgusing, started with ours at about 2k miles and was most noticable at approximately 40 mph, lasting only for a second. The noise seems to be most noticeable in colder conditions. I hardly noticed the rumble during the summer months, but now with morning temps in the upper 40's, its back. Why do we not here that Lincoln MKZ owners have the same condition,given that the platform and drivetrain are the same as the Fusion? We are still very happy with the Fusion and we also own a 2009 Milan Premier AWD with 24k, that has had no unusual drivetrain noises.

Edited September 18, 2010 by packrats

[drolds1]

I have owned a 2010 Sport AWD for a year and almost 12k miles. The rumble condition everyone has been disgusing, started with ours at about 2k miles and was most noticable at approximately 40 mph, lasting only for a second. The noise seems to be most noticeable in colder conditions. I hardly noticed the rumble during the summer months, but now with morning temps in the upper 40's, its back. Why do we not here that Lincoln MKZ owners have the same condition,given that the platform and drivetrain are the same as the Fusion? We are still very happy with the Fusion and we also own a 2009 Milan Premier AWD with 24k, that has had no unusual drivetrain noises.

 

Did you read my signature? There are very few MKZ owners here compared to the number of Fusion owners, so it follows that there aren't any other complaints . I might be the only member here with a 2010 MKZ AWD.

 

BTW, I notice no change in the condition related to ambient temps.

 

Your Milan has a different engine and transmission.

Edited September 18, 2010 by drolds1

[grump99]

Just wanted to chime in,

 

We bought a new 2010 Fusion Sport AWD in February. We started noticing the "womp" noise at about 2,500 miles (have about 9,000 miles now). Have been to the dealer about 10 times since May.

 

Torque converter was replaced. After this did not work, the entire transmission was replaced. That didn't work either.

 

At this point, the regional field engineer was called in. We did a "test drive" with his laptop hooked up to the car. He believed that the rear differential clutch was faulty. The recommendation was to replace the entire rear-end. The dealership called us after the latest repair. They told us that the noise was still present when they road tested the car.

 

My wife and I have been in contact with a Ford corporate representative. The next time we speak we are going to politely ask for our money back. If they refuse, we will be filing a complaint with our Attorney General under the lemon law statute. We hate to do it, but a $30K car should not have issues like this.

 

Good luck everyone, lets hope they get this sorted out.

[drolds1]

Just wanted to chime in,

 

We bought a new 2010 Fusion Sport AWD in February. We started noticing the "womp" noise at about 2,500 miles (have about 9,000 miles now). Have been to the dealer about 10 times since May.

 

Torque converter was replaced. After this did not work, the entire transmission was replaced. That didn't work either.

 

At this point, the regional field engineer was called in. We did a "test drive" with his laptop hooked up to the car. He believed that the rear differential clutch was faulty. The recommendation was to replace the entire rear-end. The dealership called us after the latest repair. They told us that the noise was still present when they road tested the car.

 

My wife and I have been in contact with a Ford corporate representative. The next time we speak we are going to politely ask for our money back. If they refuse, we will be filing a complaint with our Attorney General under the lemon law statute. We hate to do it, but a $30K car should not have issues like this.

 

Good luck everyone, lets hope they get this sorted out.

 

I guess these people don't talk to each other. I didn't get a new trans but among all the other parts that were replaced, one was the rear differential. I was told that the FSE reports his findings to the engineers in Dearborn. Since all the work on my car was done prior to May, if this was true the engineers should have known that the r. diff was not the answer before authorizing your dealer to replace yours.

[Fusion Focus]

anything more on this?

[grump99]

Well we have had the car to the dealership about ten times. They had the car for a total of 45 days. At least 5 major repairs have been done.

 

Ford can not find a solution to the problem. Ford has agreed to refund our money as per the lemon law. It took 7 months of persistance, but we will be turning the car in later this week. We are getting all of our money back minus $500 for usage.

 

My advice would be to keep pushing the issue until you get satisfaction. Get in touch with a Ford customer representative. It is not convienent, but it will eventually work out.

 

Good luck.

 

Tony.

[Fusion Focus]

I dont even have the car in ny possession yet but want to learn as much about these issues as possible.

Thanks

[Fusion Focus]

anybody actually got this fixed?

[fishbio31]

Can people who have taken there vehicles in with this problem please post or PM me the dealerships you went to for your problems and any case numbers. I am talking with Ford right now for the exact same problem and they are saying that I am the only one with the problem. I want to call and talk with other dealerships that have dealt with this issue. Any help appreciated.

 

We have a 2010 Sport AWD Fusion with 16,000 miles. Vibration started very early in the ownership of the vehicle. Its been in 4 times, had a shaft changed out that seemed to dampen the sound but its still there. Dealership is telling me its "normal" or they dont hear it. Frustrating

[_10579]

I am having this problem as well on my 2010 Fusion Sport AWD. Took it to the dealer and they told me it was a bad torque converter. I figured they would be wrong, but I also had a different vibration about 60MPH so I let them fix that and it got rid of that one. I still have the one at 40MPH under light acceleration. They took my Fusion back yesterday and the technician said he thought it was driveline related and wanted to see what Ford would say to do, as they had never experienced this at the dealer before. (I wanted to tell them to come to this site, but I figured I'd let them call Ford first. )

 

So I will be checking back, but it appears I got a new transmission the first time (is the TC and transmission one piece?)

 

The service manager suggested i get a tranny fluid flush but I think that would be pointless w/ a new tranny. Also, they aligned it for me, because the "subframe had to be disassembled", which was kind of nice as I needed an alignment anyways, and it saved me $40. Now I will wait to see what I hear from them.

[drolds1]

I am having this problem as well on my 2010 Fusion Sport AWD. Took it to the dealer and they told me it was a bad torque converter. I figured they would be wrong, but I also had a different vibration about 60MPH so I let them fix that and it got rid of that one. I still have the one at 40MPH under light acceleration. They took my Fusion back yesterday and the technician said he thought it was driveline related and wanted to see what Ford would say to do, as they had never experienced this at the dealer before. (I wanted to tell them to come to this site, but I figured I'd let them call Ford first. )

 

So I will be checking back, but it appears I got a new transmission the first time (is the TC and transmission one piece?)

 

The service manager suggested i get a tranny fluid flush but I think that would be pointless w/ a new tranny. Also, they aligned it for me, because the "subframe had to be disassembled", which was kind of nice as I needed an alignment anyways, and it saved me $40. Now I will wait to see what I hear from them.

 

 

If they said they replaced the TC, then you didn't get a new transmission. The TC is always a separate unit. The bottom line is what it says on your service ticket. I sincerely doubt they'd be offering to do a flush on a new trans. It won't cure anything anyway.

 

I don't want to discourage you, but after having my TC, valve body, transmission control module (TCM) and rear differential replaced, all to no avail, and being told not to expect a fix for this, I know what Ford is going to tell your dealer.

 

I don't know if you read all the posts in this thread, but the rumble is caused by the rear differential disengaging at the same time the TCC is trying to lock up. There's a brief period of "pulsing" at that point. It appears to be a software issue and any software changes in this area will have to cleared through the EPA.

 

I haven't asked for any updates recently but I'm going to do that soon. However, I'm not hopeful. One member above got Ford to buy the car back under his state's lemon law. Pursuing that route is, of course, up to you and how much this annoys you.

 

If you do hear anything, though, please post it.

Edited January 19, 2011 by drolds1

[_10579]

thanks, I have read the whole thread and saw that it was basically a software error. I will wait and see what Ford wants to do with it.

 

The tranny flush was suggested since i have 35K miles on it, and I noticed on the service ticket (mostly in dealer jargon) that it said 8 qt ATF, so I figured I got some new fluid. It was unrelated to the problems I'm experiencing.

 

Has it been determined that this wont cause any "harm" to the vehicle and its just an annoyance? If so, I can live with it, but I don't want to wear out a rear differential come 60,100 miles

[drolds1]

thanks, I have read the whole thread and saw that it was basically a software error. I will wait and see what Ford wants to do with it.

 

The tranny flush was suggested since i have 35K miles on it, and I noticed on the service ticket (mostly in dealer jargon) that it said 8 qt ATF, so I figured I got some new fluid. It was unrelated to the problems I'm experiencing.

 

Has it been determined that this wont cause any "harm" to the vehicle and its just an annoyance? If so, I can live with it, but I don't want to wear out a rear differential come 60,100 miles

 

I really have no idea if this situation will cause any long term harm. I wonder if even Ford engineers could determine that. I'm sure your dealer will say "no."

 

It'll be interesting to see what Ford tells your dealer. They once assured me that they were working on a fix. I no longer think that's the case, if it ever was.

[_10579]

Update #2:

 

Dealer had my vehicle for a week. The tech working on it was in school (I hope FORD school and not some high school kid doing my work ) which is why it took longer.

 

The svc mgr said a new rear driveshaft was installed and the problem persisted, so the next test in line that Ford had them do was "unplug the rear axle". (SHEESH these new cars have a ton of electronics. Lot different than my 89 k-1500 that I just got rid of). I don't even know what unplugging the rear axle does but regardless, doing that made the noise go away (or so they say.. time will tell).

 

So, they are giving me back the car to use while they order a new rear axle. I would have thought that those axles are like a CV, no? I know i dont have a Dana 60 under there :hysterical2: but regardless, they are now changing the rear axle hoping that will work. I will post back when I take it in again, probably should be taking the car back in sometime mid next week.

[wptski]

Update #2:

 

Dealer had my vehicle for a week. The tech working on it was in school (I hope FORD school and not some high school kid doing my work ) which is why it took longer.

 

The svc mgr said a new rear driveshaft was installed and the problem persisted, so the next test in line that Ford had them do was "unplug the rear axle". (SHEESH these new cars have a ton of electronics. Lot different than my 89 k-1500 that I just got rid of). I don't even know what unplugging the rear axle does but regardless, doing that made the noise go away (or so they say.. time will tell).

 

So, they are giving me back the car to use while they order a new rear axle. I would have thought that those axles are like a CV, no? I know i dont have a Dana 60 under there :hysterical2: but regardless, they are now changing the rear axle hoping that will work. I will post back when I take it in again, probably should be taking the car back in sometime mid next week.

That's the hard way! Just pull the fuse to disable the 4WD/AWD module.

[_10579]

That's the hard way! Just pull the fuse to disable the 4WD/AWD module.

 

the dealer seems pretty confident that this will fix the problem. only time will tell i suppose..

[wptski]

the dealer seems pretty confident that this will fix the problem. only time will tell i suppose..

Huh! That will defeat your 4WD/AWD rearend ATC unit. If that stops your problem, you need a new rearend, they aren't servicable.

[_10579]

Huh! That will defeat your 4WD/AWD rearend ATC unit. If that stops your problem, you need a new rearend, they aren't servicable.

 

no, that is what they are doing. Sorry, I guess I wasn't clear in my post, that they are replacing the whole rear end.