Solved: Trunk Rattle

[klatoo]

Like many others, I had the ubiquitous rear trunk rattle. Check the plastic piece between the rear trunk bars, drove around and around my neighborhood with my wife walking alongside it, riding in the back, riding with the seats down, etc etc until one day I noticed the sound went away as soon as the car was turned off. Turn it back on, rattle rattle rattle again. Thought maybe it was the radio but the sound got louder on the interstate and quieter when parked at a red light, light traffic, etc. After 3 weeks of head banging against the wall and driveway, wifely opens the little door where the battery shut off is and low and behold, loud butt click click click.

 

Took to Ford, come to fine out the fan was broken that's part of the hybrid battery cooling system. Apparently there are 2 down there...one at the bottom left and one at the top right.

 

DG9Z10C659C Fan Assembly. Apparently there is a 10C659B as well...that's not the right part according to the service rep.

 

That's the culprit. If you have this problem, there you go. Only took the dealer 3 days to figure it out...had to bring the hybrid master mechanic from the other store to figure it out apparently.

 

http://parts.lakelandford.com/a/Ford__C-Max20L-ELECTRICGAS--Automatic-CVT/52539808__6477663/Hybrid-Battery-Cooling/JG13094.html

 

http://www.fordparts.com/Commerce/PartDetail.aspx?n=Ikll31yrg3K82zRAqtkC6A%3d%3d&id=319441385&m=2&search=true&year=2013&make=Ford&model=Fusion

 

$142.03, that's what Ford charged themselves plus $56 bucks for the install.

 

[securityguy]

No rattle here but, I do hear one, I now know where to look first. Thanks!

[usererror]

Thanks for this info. I recall when I was test driving the Fusion a sales person at one dealer mentioned there were problems with fans on the Lincoln version...I would have assumed that the fans would have been the same on the Fusion and MKZ hybrids since they aren't visible.

[Steven Mcqueen]

I took my 2015 in today for the rattle - of course they couldn't hear it and I took the tech out and couldn't replicate - I got 3 miles from home and it started - I don't know if it is the seats or the torsion bars - I put foam between the torsion bars and the truck lid and will report

[klatoo]

Unsure how far away from the dealer you live but it does take a few miles to get the batteries all warmed up before the fan starts it's sing of death. Whole time I was driving to the dealer there was no noise till a quarter mile from the dealer.

 

I've learned from previous occurrences to have the rep sit or ride in the car with you and point out when the rattle occurs. Thankfully when I brought mine in only a deaf person couldn't hear the rattle.. especially when I opened the battery disconnect hatch and it was evident even in a loud working environment.

[Riggo]

I have the rattle but not always when the car is on. Took it to the dealer and the replaced the trunk seal. The rattle stopped on my drive home until I opened and closed the trunk. My next trip the rattle returned. So frustrating.

[GrySql]

Riggo, you're back, it's been a while! :hi5:

[Riggo]

Yep. Sadly it's for the rattle problem ?

I love the car but the rattles are so frustrating.

[scn101]

I'm not sure if this will help but I lessened (perhaps eliminated) a rattle from the right rear passenger door area by removing the back seat lower cushion and locating the wiring bundles under the seat. They were loose (to the point that I could see them rattling at speed) so I slid some damper foam under them so they can't rattle. There were about 3 or 4 things that looked like they could rattle and I damper foamed them all and put the seat cushion back on. So far it seems to have helped. And while you're there, make sure you treat the leather that rubs on anything (making it somewhat slick stops squeaks). Same thing for all the door weatherstripping, use dielectric grease (best) or Armor All (ok).

 

To remove the cushion locate two levers in the front of the cushion at floor level. Slide the lever while gently pulling up on the cushion. Once both sides are released tilt the cushion up as far as possible and it will pop off. Remove from vehicle. Replace same way, it will automatically latch in when pushed down.