cracking noise

[hybridbear]

Either way its at the dealer... Will report back EOD hopefully I don't have to keep my rental too long @ $35/day.

 

Why on earth are you having to pay for a rental?? When the car is under warranty Ford pays for your rental if they need the car overnight. The dealer will do all the arranging for you even

Edited April 5, 2013 by hybridbear

[acdii]

Why on earth are you having to pay for a rental?? When the car is under warranty Ford pays for your rental if they need the car overnight. The dealer will do all the arranging for you even

Thats what I was wondering myself.

[sleamiller]

My fusion hybrid started doing this 3/30 around 650 miles. Took to the dealer this last week and they said it is a known problem and called the hotline. They would have to get back to me with a final solution. The engineers are supposed to be working on the problem. My dealer said he thought the axle needed replacement and it would be a recall thing. I tweeted Ford for help and got voice mail message this morning stating my dealer will be in contact with me. I understand if they are trying to find the root of the problem and I am fine with that but everyone who hears a noice like the ones described should take their car to their dealership. This problem needs to be logged in and addressed and people should be vocal about it. The noise in my car was a popping that I thought was engine related. As I slowed coming to a red light in EV it would make a knocking sound at the very slowest speed. Then when I ease off the light slowly it pops again.

[acdii]

Mine did that too. My wife noticed it while standing outside the car and said, that doesnt sound right. I heard it when going from dead stop, and slowly rolling forward, and again when I slow to a stop. Like a Click thunk. To me it sounded like something engaging, or disengaging.

[expresspotato]

Why mine says its the brakes then meh... Ford's money! They should release a recall / notice to dealers otherwise its parts down the tube.

[acdii]

Brakes make a distinctive sound, so if that is what they are hearing, then it could be a different thing, however, brake pads rarely make a big enough sound to be heard inside unless they are sticking, in which case there are bigger issues, Loose pads also rattle when not in use. If what you are hearing is the same sound I, and what others describe, it is not the pads.

[B25Nut]

Mine has been making the sound for more than a month. My first thought when I heard it was it's almost exactly the same sound my Chrysler Pacifica started making after the same number of miles while turning a slow speeds. A new transfer case eliminated the sound, but it reappeared at 115K miles. Chrysler didn't have a recall on it, since it wasn't considered a safety issue. Common sense tells us, however, that any part making a sound will eventually have premature wear. Is the noise occuring on non-hybrid Fusions?

Edited April 7, 2013 by B25Nut

[Da0ne]

Noticed mine is doing the same clicking sound when I stop or drive away this weekend

[expresspotato]

Update: They replaced the front brake pads on both sides and it didn't make a difference. Two CV Shafts have been ordered from the USA and should be here in 2-3 days. Maybe they'll be an updated part? Maybe not...

[acdii]

Update: They replaced the front brake pads on both sides and it didn't make a difference. Two CV Shafts have been ordered from the USA and should be here in 2-3 days. Maybe they'll be an updated part? Maybe not...

I had my doubts, but waited until you confirmed it. Here's why, brake pads that are loose in the calipers dont clunk, they click, and you would have some very noisy brakes in the Hybrid had they been that loose. Every time you stopped you would hear them as they would squeal like a WWII Jeep! I heard the exact noise you are referring too, and I can say 100% that was not a brake pad noise, but a driveline noise. The loose axle shaft is the most logical explanation for the noise I heard.

[rvlasek]

Update: They replaced the front brake pads on both sides and it didn't make a difference. Two CV Shafts have been ordered from the USA and should be here in 2-3 days. Maybe they'll be an updated part? Maybe not...

 

Please update forum on results of CV shafts servcie, I'm taking in tomorrow for "Battery Power Saver System Off". issue, think I have a defective starter battery, and will follow if any results from Ford about my Hotline assistance case #, pertaining to the

 

noise , crackling issue....

Edited April 9, 2013 by rvlasek

[rhefley]

Does anyone on here have a TSB number for the issue. My local dealer says they are unaware of the problem? The need a technical service number. I am having the same problems and it does sound horrible.

[hybridbear]

Does anyone on here have a TSB number for the issue. My local dealer says they are unaware of the problem? The need a technical service number. I am having the same problems and it does sound horrible.

 

Reference post #46

 

Ford Hotline Assistance Request 10619892

[hybridbear]

The dealer confirmed that our car has this same issue. We hadn't heard it, but the technician did. He is ordering a new axle. Someone earlier mentioned that the Ford Hotline said not to replace parts because Ford hasn't solved the issue yet. He said that the Ford Hotline told him to replace the axle and put extra grease on it to temporarily mitigate the noise. Ford does not know how long that will keep the noise away but they say that replacing the axle is not a permanent fix.

 

Has anyone else been told this? I'd suggest that anyone who hasn't gotten their vehicle logged at Ford for this issue who hears this noise should get it reported to the dealer along with the information from this thread. It really helped my dealer.

[Harbor]

What a great forum. Hello all.

 

My 2013 Fusion Hybrid SE also started doing this about 10 days ago at 1300 miles. After seeing the posts here I called my dealer in NH. They were already aware of the issue and told me I would have to wait until the official fix process was approved by corporate. No need for an appt just yet.

 

So like the rest of us, I'll have to wait it out. It just kills me when people say "wow your car is so quiet.. followed up shortly with WHAT WAS THAT?" And I am forced to reply "1st year models.. made in Mexico.. you know how that goes".

 

The service dept did say they *believed* the eventual fix would involve replacing the "cv stub". If anyone has any guesses to what that means technically it would be appreciated.

 

Thanks

 

-Harbor

[Riggo]

What a great forum. Hello all.

 

My 2013 Fusion Hybrid SE also started doing this about 10 days ago at 1300 miles. After seeing the posts here I called my dealer in NH. They were already aware of the issue and told me I would have to wait until the official fix process was approved by corporate. No need for an appt just yet.

 

So like the rest of us, I'll have to wait it out. It just kills me when people say "wow your car is so quiet.. followed up shortly with WHAT WAS THAT?" And I am forced to reply "1st year models.. made in Mexico.. you know how that goes".

 

The service dept did say they *believed* the eventual fix would involve replacing the "cv stub". If anyone has any guesses to what that means technically it would be appreciated.

 

Thanks

 

-Harbor

 

Oh lovely, it sounds like a major recall is on the horizon.

[rvlasek]

Same info I got today from my dealer here in Texas,, no fix yet but working on it.. I was told to check back in three weeks with my Ford Hotline case number...

[rhefley]

Reference post #46

 

Ford Hotline Assistance Request 10619892

When I gave the service man this number he said it is Not a TSB (techincal service bulletin) Number, is this exactly how it reads or is there anything missing. He said it usually has dashes in it. Maybe he just didn't want to help??

[jv92694]

I have a 2013 SE Hybrid with the same kind of issue - sounds almost like a ping pong ball is bouncing around inside the wheel well. I did not notice it on the test drive and my wife was really against me buying this vehicle so now she is riding me hard to get it fixed - same out come as noted above - Rancho Santa Margarita Ford in Orange County said they did fix one with this problem but Ford has since told them NOT to repair any further vehicles until a "permanent solution" is found. I find this totally unacceptable and am considering pursuing lemon law type action as it is not acceptable for a brand new car to behave this way. If Ford knows about it and has no answer, there should be compensation of some kind. I was financed through Ford Motor Credit and feel like giving it back to them (I know, can't do it but sure want to!) I am also only averaging 39 miles to the gallon but that is still better than most cars. I was also told that if you put it in cruise at 62 you could get up to 100mpg. I just finished a road trip trying to use that technique as much as humanly possible and only got the mpg to 40. I get raves from the looks but as soon as someone goes for a ride with me they always ask, what is that noise?

[jv92694]

OH, forgot to mention, one of the letters came off on my last car wash, the I in Fusion... nice quality Ford!!!!

[acdii]

 

The service dept did say they *believed* the eventual fix would involve replacing the "cv stub". If anyone has any guesses to what that means technically it would be appreciated.

 

Thanks

 

-Harbor

The CV stub is the axle portion of the CV, or Constant Velocity shaft. AKA, your axle. In FWD the axle has to turn with the front wheels so it has ball bearings inside of two cups. This part is attached to the wheel. The part they are referring to is the actual shaft that connects to the transmission. I know the sound everyone refers too, I heard it as well. There is some slop in the shaft, where exactly, unknown, but my guess is Ford is working on a kit to resolve this, and until then they dont want to be throwing parts at it and they arent concerned about safety or excess wear, yet. It most likely will just be a sleeve to take up the slop, or a different shaft that they will swap out of the CV joint instead.

 

I wouldnt be too concerned at this point, I had 8400 miles on mine and the click never got worse, was always the same.

[hybridbear]

When I gave the service man this number he said it is Not a TSB (techincal service bulletin) Number, is this exactly how it reads or is there anything missing. He said it usually has dashes in it. Maybe he just didn't want to help??

This isn't a TSB yet. Ford will come out with a TSB once they have a solution. For now there is just a Ford Hotline Case Number. Your dealer contacts the Ford Hotline when they are confused or stumped as to an issue to see if other dealers or Ford Engineering has encountered this issue. When they do that there is a Case Number created with the Ford Hotline. The issue then rests with Ford Engineering to solve. The Ford Hotline number for this issue is listed numerous times in this thread. Give your dealer that number and tell them you think that your issue is the same as what's referenced in that Hotline Case. Then the technician can contact the Hotline for more details and confirm/deny if your noise is the same. If it is the same then your car will be logged with Ford as one more with this same issue and will help them solve it by adding more data points. That is why it is very important to make sure your dealer logs the issue with Ford under this one Case Number. Giving Ford as much data as possible will help them isolate and solve the problem more quickly.

 

I have a 2013 SE Hybrid with the same kind of issue - sounds almost like a ping pong ball is bouncing around inside the wheel well. I did not notice it on the test drive and my wife was really against me buying this vehicle so now she is riding me hard to get it fixed - same out come as noted above - Rancho Santa Margarita Ford in Orange County said they did fix one with this problem but Ford has since told them NOT to repair any further vehicles until a "permanent solution" is found. I find this totally unacceptable and am considering pursuing lemon law type action as it is not acceptable for a brand new car to behave this way. If Ford knows about it and has no answer, there should be compensation of some kind. I was financed through Ford Motor Credit and feel like giving it back to them (I know, can't do it but sure want to!) I am also only averaging 39 miles to the gallon but that is still better than most cars. I was also told that if you put it in cruise at 62 you could get up to 100mpg. I just finished a road trip trying to use that technique as much as humanly possible and only got the mpg to 40. I get raves from the looks but as soon as someone goes for a ride with me they always ask, what is that noise?

Whoever told you that you could get 100 MPG is incorrect. If the car is EPA rated at 47 MPG highway how are you going to get 100 MPG? Even experienced Prius hypermilers can't do that on the highway at 62 MPH.

 

As far as Lemon Law, you need to check the rules in your state. In MN a Lemon Law claim requires multiple failed attempts for the same issue or 30 days in the shop within the first 2 years of ownership, or one failed attempt to fix a safety issue involving the brakes, etc. This doesn't count as a safety issue, just an annoyance. That's the risk we all took buying the first year of the new style Fusion

[rvlasek]

When I gave the service man this number he said it is Not a TSB (techincal service bulletin) Number, is this exactly how it reads or is there anything missing. He said it usually has dashes in it. Maybe he just didn't want to help??

I agree with Hybridbear,, the Ford Hotline Assistance Request 106198928 number shoud be refered when you check in with your local Ford Service for front cracklin noise issue, may be other case number, but this is one I was issued...hopefully the Ford engineers come up with fix...they kept mine for 4 days trying to figure it out, changed front strut with no luck on noise solution...

[acdii]

I forwarded the case numbers off to my dealer, hopefully it will save him some time in the future to make up for the time they wasted trying to find the issue with the one I had.

[Riggo]

I agree with Hybridbear,, the Ford Hotline Assistance Request 106198928 number shoud be refered when you check in with your local Ford Service for front cracklin noise issue, may be other case number, but this is one I was issued...hopefully the Ford engineers come up with fix...they kept mine for 4 days trying to figure it out, changed front strut with no luck on noise solution...

 

This is pretty disturbing that my brand new car is likely going to end up having to have this repaired like the rest of you. It seems like it's a problem with everyone, no? :petting: