cincidaddi

I recieved my FFH after 6 days in service. After driving it for the last 3 days all appears to be back to normal. I'll post again if anything changes.

To follow up, it was confirmed that my car needs the transmission replaced. They received the new transmission 3 days later and the replacement is now underway. I have a loaner Fusion for the estimated week it will take. For the issue tracking topic: my vehicle was built Nov 2012 and it had 40K miles when the noise was noticed.

I'm experiencing a very similar noise as described in this thread on my 2013 Fusion Hybrid SE. Light grinding and thumping noise mostly noticable in EV mode. I thought it may be the electrical generator/motor. The posts on this thread are spot on and I've made a service appointment for next week. Hopefully the dealer will take the associated TSB and not waste any time in getting it fixed. This amazing forum has helped me cut through so many chases!

I had the same reaction at Kerry Ford in Cincinnati, OH. One of the service techs working on it directly told me they don't see how this will make any difference. The repair has made a HUGE difference. I think their sense of smell is directly affected by the significant job it is to remove and replace the dash. Everything eventually went back to normal after the repair with one exception of a .5" gap across where the dash meets the windshield. The gap exposes some black foam material, but no rattles or other anomalies. I pointed the gap out to the service advisor and he says they will have to pull everything out again to fix it and it wasn't worth it.

I've got a black 2013 FFH myself with black interior in Ohio. Good for cold, bad for hot but I knew that going in. I absolutely love the look. To mitigate heat, I tinted my windows, use remote start and global open. The global open feature on your remote allows you to open all windows (and vent sunroof if you have one) by clicking then holding the unlock button for 3 seconds. I do see similar impact to fuel economy when running A/C in hot temps. Aside from the A/C energy sink, I would imagine the elevated engine and battery temps may also drain efficiency.

That's an interesting find, I didn't know to ask that question regarding the synching. I've already gotten the car back and they said they replaced the motor. Apparently they ran through a number of checks before finally replacing the motor. The root cause shall remain a mystery to me. Not sure why the wipers would have ever been touched/reversed. But anything is possible. The other goofy thing that happened came was my key getting broken. I'm not sure how, but they cracked the housing and made it so the release button would not work. They wound up replacing it, but it cost me yet another trip to there.

To follow up on my post a couple of days ago regarding the completion of TSB 14-0099... all was well until I tried my windshield wipers for the first time since the TSB was completed. They had worked perfectly prior but would not come on. The wipers moved about an inch and stopped. I took the car back to the dealer today and they said it is caused by a faulty wiper motor that needs to be replaced. The resistance of the motor was 4 times what it should read. The service advisor told me it was a complete coincidence that the motor went out and it had nothing to do with the removal of the entire dash. Really???? I'm curious to know if anyone else winds up with non-working wipers. Could it be possible for wiring of the wiper controls on the steering column causing a short? Or could it be that during the disassembly/assembly process the mechanics accidentally engaged/shorted the wires and screwed up the motor? Nevertheless a wiper motor was ordered and it is supposed to be replaced tomorrow.

My repair was completed yesterday for the bad smell from the a/c, per the Ford TSB 14-0099. I must say it made me rather nervous to see the heart and lungs of my car come out like it did (pictures below) but everything seems to be back in place and after day 1 of driving it. I've not noticed anything loose, broken, squeaking, or not operating. Best of all of course, the air smells normal! I don't have to be embarrased when giving someone a ride anymore. I'll give it about 6000 warm weather miles before declaring victory, but so far so good and my fingers remain crossed. BTW, it took 2 solid days for them to do the work, and I overheard the grumbling from the mechanics on how difficult it was. I was tempted to ask if I could keep the defective unit so that I could dissect it. I wanted to take pictures of exactly what it is on the inside that was the root cause of the smell and post them. However, I assumed they would need to send it back to Ford and I didn't bother asking.

I live in SW Ohio. The smell started last summer around 8000 miles for me but it was faint. It went away during the winter then in the April as the temperature went up to 80 degrees, it's back and stronger. I have it now consistently whenever I start up the A/C though it will subside after about 10 minutes of running it. I would describe it as disturbing but not yet unbearbable. It is definitely progressing in repeatablility and stench as temperatures are steadily rising.

I live in SW Ohio. The smell started last summer around 8000 miles for me but it was faint. It went away during the winter then in the April as the temperature went up to 80 degrees, it's back and stronger. I have it now consistently whenever I start up the A/C though it will subside after about 10 minutes of running it. I would describe it as disturbing but not yet unbearbable. It is definitely progressing in repeatablility and stench as temperatures are steadily rising.

My 2013 FFH has the smell issue as well and I'm glad to see they finally have a TSB available. I went to my dealer after reading this thread yesterday. I was told I need to bring it in first for an appointment next Tuesday to validate that this is the problem. Once they confirm, he said they will order the parts and perform the job. I'm a little peeved it couldn't be done earlier than that.

I have the same problem and concern with the license plate.

This is why I'm not convinced its 100% normal. It doesn't happen to me when the brakes are dry. Seems like the braking system should compensate better if transitioning when wet.