My 2013 Fusion Hybrid, built 10/31/2012, was making this grinding noise, seemingly when the regen braking was active. It also started a loud whine when coming to a stop. I drove it that way for about 1000 miles and took it to the dealer with 96,750 miles on the car. They had it exactly two months while I drove the dealership's loaner. I got it back today, finally fixed! They told me parts back ordered but I suspect it was not looked at for the first 4 weeks (they told me at 2.5 weeks that they hadn't gotten it in yet).
The paperwork says:
SEE TSB 16-0105
REMOVE TRANS, DISASSEMBLE TRANS FOUND DAMAGE ON TRANSFER SHAFT BEARINGS. INSTALL TRANSFER SHAFT KIT AND REINSTALL TRANS. FLUSH FLUID COOLING SYSTEM. TOP OFF COOLANT AND TRANS FLUID. SET FRONT TOE. TEST DRIVE OK AT THIS TIME.
Hoping this was a permanent fix to the issue. Any idea why they "SET FRONT TOE"?