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I don’t know what’s required for a 2010 Fusion Hybrid. When I replaced the transmission in my 2013, I did notice some slight shuttering/vibration when transitioning between ICE and electric modes. I just figured that was because I had mated a brand new transmission from a flooded car on a dealer lot with a 6 year old engine and there just wasn’t a perfect mesh between the components and gears. Swapping transmission control unit or recalibration may have helped that but it wasn’t a major concern, the car operated just fine.

I replaced my 2013 transmission that had the known bearing issue from the 2013-2015 models around the same mileage point (140,000) in 2020. I sourced a low mileage 2016+ transmission from a C-Max or Fusion Hybrid (NOT Energi) and had a shop replace it, with my assistance. Cost around $3000 total. I have 190,000 miles on mine now, value of my car is likely closer to $4000 now. I don’t treat mine as well as others but it gets all the required maintenance and doesn’t show signs of stopping. Fuel mileage is suffering due to battery age but it’s still over 37mpg (10-15% loss) and even then the engine is pretty efficient on its own compared to late model sedans. Backup camera has died. Trim is starting to show its age. If you plan on driving it until it stops working then even a $7000 bill seems more reasonable than a newer vehicle and you can get a good amount more years out of it.

HF35 is part of the 8 year 100,000 mile hybrid powertrain warranty. Check when you first got it diagnosed or brought up the concern and push for warranty repair if you brought it up within that 8 year window from delivery. I paid $1500 for a junkyard totaled (flood) low mileage 2016 HF35 and $1000 for labor in my 2013, with me providing some of the labor but using tools and expertise from others. Original transmission replaced at 130,000 miles in 2020, now at 180,000.

It’s been a while since I have looked at an exploded view or parts list but I want to say that Tasca Ford had some of the transmission internals available for purchase if you know the part number but I opted for a junkyard transaxle on my 2013 when the bearings started going bad. I never did determine which bearing was bad in my unit.

I believe a donor has to be a Cmax or fusion hybrid only. The energi models have a different gear ratio.

This transmission design is shared with some Toyotas. Here’s a diagnostic procedure which appears to check for a short in the MG1 circuit from a Toyota source. https://share.qclt.com/丰田普瑞斯原厂英文手册pdf格式/repair manual/04pruisr/05/21bpm/0a92521.pdf Makes sense if the ECU detects a short in the MG1 circuit it won’t allow the ICE to start. You have a 2013 with over 100k miles so it may soon start showing signs of the transmission bearing issues that plagued 2013-2015 models, may be worth finding a junkyard 2016+ transaxle regardless.

2013-2015 transmissions could have a bearing issue. see:

www.car-part.com look for 2016 or newer fusion hybrid or c-max transmission I got one from a flooded 2016 cmax with less than 1000 miles on it for about $1500 shipped.

I purchased a service manual subscription from AllDataDIY when I performed a transmission swap. I recall there being a section about the harmonic balancer in there. IIRC the “subscription” was $25 for one year per vehicle and was a really good reference.

Check this thread. Seems like a bearing going out. Somewhat common on 2013-2015.

Could be a transmission bearing going out. Seems to be somewhat common on 2013-2015 year models from 30k to 150k+ miles. Mine started giving me rattling/bearing noise when the ICE was on at 130k. It was not the transfer shaft bearings as noted on TSB and from other owners, mine seems to have been the ATF pump shaft bearing. If you’re under 100k miles it should still be under warranty for the hybrid drivetrain components. Dealer needs to dive deeper.

2013-2015 The official dreaded transmission issue is a bad transfer shaft bearing. Mine started having issues at 140k miles and I thought it was the transfer shaft but it seems to have been the engine input/generator shaft, which would make noises when not moving. I haven’t been able to research if I can replace what parts I think are worn in that shaft assembly.

Car-part.com and dug around to find low miles, newer model, and no front end or axle damage. The rest was putting the puzzle pieces together on the flood status and contacting the dealership on the window sticker.

We've replaced my transmission with one off a "new" 2017 C-Max that had flooded in Hurricane Harvey. 42 Miles on the new transmission. C-Max was in a junkyard in Illinois and still had window sticker on it so I saw it came from Mac Haik Ford in Pasadena, TX which is just down the road from me. Due to the year model and flood status and original location I knew this was a Harvey Flood car and I knew even cars that barely had wet floorboards were totaled. I called Mac Haik and they confirmed all the C-Maxes had water to just the floorboards, which was well below the trans vent. I purchased it and when it arrived I looked inside the axle spline holes and no sign of rust or contaminants. What little ATF was left in there that came out as we were moving it around was bright red and clean. Good resource for the manual for performing the work is available from AllDataDIY. Highly recommend a car lift, material handling equipment, and transmission jack as the subframe needs to be removed. The engine doesn't have to come out but it may make it easier, we elected to leave the engine in. Removal took about 6 hours, install took about the same. Two or more sets of hands on it at all times. We opened up my old transmission and determined the transfer shaft and bearings appear to be OK. The ICE and generator motor share a shaft through a planetary gearset and it appeared to be a a little wobbly which may be the root of my issues or its interface with the trans fluid pump. Trans input shaft seal appeared to have a small leak (maybe due to the vibrations/etc in that shaft. The passenger side axle shaft seal appeared to have a minor leak as well. Neither left puddles under the car or in the bellhousing. I do not know if there are replacement parts for that ICE shaft so I do not know if I will be able to refurbish the old transmission.

See if there's another dealer nearby that has performed this work previously. Less likely it would get messed up and more likely to understand the implications of the warranty.