hybrid47

Mattken's first posts back in January indicated that he was already in arbitration working towards a buyback, this would lead me to believe that any work by Ford on his Ford Fusion, such as the evaporator replacement, had already occurred prior to that point and prior to the release of Ford's TSB in May.

Here is a copy of the latest Customer Satisfaction Program bulletin from Ford dated 6/12/2014. 14B03.pdf

This may be a case of apples vs. oranges when trying to compare Mattken's repair to the TSB repair, since we do not know whether his repair was completed before or after the TSB was issued. What I mean by this is, that Mattken may have had his evaporator replaced, but with a stock part, long before the TSB was issued, and not with the redesigned part that Ford is recommending be used in the TSB repair. If this is the case, then his smell may have very well come back fairly soon, while those with the new revised evaporator coil assembly, per the TSB, are not having any reoccurrence of the smell problem. Mattken will have to provide clarity on what parts were used in his repair, before we can come to any conclusions. By the way, my 2013 Ford Fusion Hybrid also has the smelly AC problem, since about 6 months old, and the thought of having the whole dash taken out to repair this is not making me a bit happy.

Whoops, another Ruby Red, I didn't know that this color was so popular!

Added!

I did not experience any error codes after I installed my new aluminum accelerator pedal assembly, but I did disconnect the battery before I started the job. Your experience at the dealer makes me wonder if they tried to install the new pedal assembly without disconnecting the battery! The vehicles computer and electrical systems are always in standby mode even when the car is "off", so I just consider it a good practice to power everything down before disconnecting any interfaces to the engine management computer, like the accelerator pedal position sensor assembly. Hopefully they didn't cause any permanent/latent damage and only generated a few error codes (ouch!).

Here are some instructions for installing the Aluminum pedals on a 2013 Ford Fusion Hybrid SE. The old brake pedal pad is simply pried off, and the new pedal pad must be carefully levered onto the bake pedal assembly, using a small putty knife and/or some screwdrivers, being careful not to tear the rubber backing on the new part. Since the rubber on the new aluminum pedal pad is fairly stiff, I found it helpful to warm the part with a hairdryer first, to make it more flexible, so it would go on easier. As noted by another poster on this thread, you cannot get just the pad for the accelerator pedal and must purchase the whole assembly if you want the aluminum pedal pad. The old accelerator pedal assembly has one torx head bolt at the top of the part holding it on (behind the wiring connector), and once the bolt is removed, the part can be slid upward and out to free the remaining mounting ears that hold the peice in place. Once the part is free, carefully pull it downward so you can access the wiring connector at the top of the assembly, and using a very small screwdriver, push in the connector locking tab, while pulling up on the wiring connector, to remove it from the pedal assembly. Re-assembly is just the reverse of the removal, first plug the wiring connector into the new accelerator pedal assembly, making sure that it locks in place, then position the part back in the footwell just above the original parts position, and push the part back in and downward to engage the mounting ear tabs in the slots in the footwell. Once the part is locked back into it's proper position, re-install the single torx head bolt into the hole at the top of the new accelerator pedal assembly and tighten, to complete the installation. For those that would like to make the switch to aluminum pedals, here are the part numbers, and Ford's list price for the parts: 1. Aluminum 2013 Ford Fusion Hybrid gas pedal assembly part number: DG9Z 9F836 C list price $69.91 2. Aluminum 2013 Ford Fusion brake pedal pad part number: DG9Z 2454 C list price $34.73

Neod192, I did the conversion on my Hybrid SE, see the link and photos below: http://fordfusionhybridforum.com/topic/6042-titanium-pedals-and-lighted-door-sill-plates/ Cheers!

I do not know if this is related, but discusions of a similar start/stop noise, on another forum led to a conclusion that the noise was coming from the brake pads shucking in the calipers upon acceleration/deceleration. It appeared that the brake pads did not have shim springs that were tight enough to keep the pads from moving around in the calipers. Could the metalic sound you are hearing be coming from the general location of the front brake pads/calipers?

As I had noted in my earlier post, I did not go to my dealer with this problem, but instead wrote to Ford in an E-mail, regarding the issue with the incorrect shifter having been installed in my Ford Fusion Hybrid SE with the 505A package. It took Ford a little over four weeks to respond to my E-mail this time, but they did acknowledge the build problem and referred the issue to my regional Ford manager for resolution. The regional Ford manager called me several days after I received the E-mail reply from Ford, and discussed the problem with me and initiated the ordering of the correct leather replacement shifter, which he had sent directly to my local dealer. My local dealer called several days later to say that they had received the replacement shifter, and that they would like to setup an appointment to have the new shift knob installed. I had it installed this week, and as you can see by the photo below, all is well in my Ford Fusion Hybrid garage!

This just goes to show that Ford's dealer training isn't all that it could or should be.

I talked with Ford regarding the 18 inch wheel package, and they advised that the larger wheels and tires are required when the Ford Fusion is ordered with the SE Luxury Driver Assist Package. When I questioned them further, they said that the Lane keeping System that is part of the SE Luxury package is calibrated to the 18 inch wheel and tire package (part of the cars computer programming), and the car needed to have the larger wheels and tires so that the Lane Keeping system would function properly. So far my lifetime average fuel mileage is 40.2 MPG, so I can't say for sure whether the 18 inch tires are causing any reduction in fuel milelage, but if what Ford is saying is true, I won't be switching back to 17 inch wheels and tires to confirm it.

The instructions with the lighted door sill plates are very good, since those are an official Ford accessory item. The sill plates get power from two wires going to the back of a connector in the overhead light console (behind the sunglass holder and map lights). The cables then run down the front drivers side A-pillar to the footwell, and then split apart underneath the dash to each side of the car and down behind the left and right footwell kick plates to the two door sill plates. You have to pull or remove about a dozen different panels to get access to run the wires, so you would need to feel comfortable with doing that, but other than taking allot of time to do it correctly, the job itself is not that difficult to do. You do need to solder a couple of wires together, for the power connection, since there is no dedicated wire connector for the sill plates to get power from (you need to supply your own soldering iron, solder and electrical tape). The kit includes a generous supply of wire ties to keep everything looking neat and tidy. The sill plates are lighted from a single LED each, that feeds into a plastic fiber optic light pipe going to each of the letters in the word "Fusion" to light it up (pretty cool). The sill plate lights come on when you open the door and dim down to off in unison with the overhead lights.

Thanks for the clarification on the date.

My car is still not fully broke in yet, but these are the latest stats that I just pulled from the information display: Current mileage: 970 EV: 169.4 Regen: 27.6 Avg MPG: 40.2 Avg Brake Score: 94% Gallons used: 24 I must admit that I do not do anything special as far as driving it like a "Hybrid", and on numerous occasions I have driven it like I stole it, so I am sure that I could get the numbers up higher if I tried.