2011 Fusion Sport body panel alignments

[djdcz1]

I noticed the front end doesn't line up correctly with the front fenders. It's more apparent on the driver side.

 

There is a 1/4" gap, drivers side, were the front fender meets the front end. You can see the back of the headlight thru the gap. Also, the front fender sticks out about a 1/8" more then the front end, were they meet.

 

Finally, the passenger side mirror outer shell has a seal going all the way around it and the bottom portion of the outer shell seal doesn't make full contact with the door. The seals purpose is to keep water from getting behind the outer shell. After washing my car I can push on the outer shell, which will make the seal contact the door, and water will come out. The drivers side mirrors outer shell makes good/tight contact with the door.

 

Sorry, If i haven't explained very well, but I'll try to attach some pics of the areas I'm talking about.

 

Plan on taking it to the dealer soon and see what they say.

 

Has anyone else noticed these issues?

[Keldon]

I noticed the front end doesn't line up correctly with the front fenders. It's more apparent on the driver side.

 

There is a 1/4" gap, drivers side, were the front fender meets the front end. You can see the back of the headlight thru the gap. Also, the front fender sticks out about a 1/8" more then the front end, were they meet.

 

Finally, the passenger side mirror outer shell has a seal going all the way around it and the bottom portion of the outer shell seal doesn't make full contact with the door. The seals purpose is to keep water from getting behind the outer shell. After washing my car I can push on the outer shell, which will make the seal contact the door, and water will come out. The drivers side mirrors outer shell makes good/tight contact with the door.

 

Sorry, If i haven't explained very well, but I'll try to attach some pics of the areas I'm talking about.

 

Plan on taking it to the dealer soon and see what they say.

 

Has anyone else noticed these issues?

 

Yikes. I hate to even think it, but are you sure the car wasn't damaged and repaired before u bought it? The gaps and misalignment you described don't sound right. About the mirror, I can't really comment. I've not noticed anything like that, but I haven't really looked either. I did find a piece of rubber seal around the top of a rear door sticking out farther than the others, and managed to tuck it into place. Then there's the headlight problems I've been having. One already replaced, the other this week. And don't get me started about Sync. Or as my son calls it, Suck. So I have to say, I'm not overly impressed with the quality of my Fusion thus far.

[turtlejj]

I noticed the front end doesn't line up correctly with the front fenders. It's more apparent on the driver side.

 

There is a 1/4" gap, drivers side, were the front fender meets the front end. You can see the back of the headlight thru the gap. Also, the front fender sticks out about a 1/8" more then the front end, were they meet.

 

I just noticed this issue on our car the other day. It's worse on the driver side (image attached). I'm surprised I hadn't seen it earlier. It's not quite a 1/4" but big enough that it looks like crap. Perhaps something has loosened up since we've had it. Guess I need to go to a dealer and see some others for comparison. I really don't want someone tearing into it and messing something else up in the process so I'm just living with it for now anyway.

[djdcz1]

I just noticed this issue on our car the other day. It's worse on the driver side (image attached). I'm surprised I hadn't seen it earlier. It's not quite a 1/4" but big enough that it looks like crap. Perhaps something has loosened up since we've had it. Guess I need to go to a dealer and see some others for comparison. I really don't want someone tearing into it and messing something else up in the process so I'm just living with it for now anyway.

 

 

It doesn't appear to be from damage.

 

It seems to be misaligned from the factory. Either some bad assembly (missing bolts) or bad engineering (bolt/hole placements). I couldn't find any missing/loose bolts.

 

Besides that I'm loving the 2011 sport.

 

I'm just really anal when it comes to the body.

 

Might just have to live with too, since I would hate the dealer having to remove panels.

[djdcz1]

 

Turtle,

 

Your pic looks exactly like how my fenders are lining up.

[blumagic]

After reading these posts mine is lined up the same exact way...

[autoxr1]

Wow! Something is definitely wrong with that seam alignment. My 2010 Sport is much more even.

 

[toyotasucks]

I just got a new 2010 sport a few weeks ago and it looks just like turtlejj's pic on both sides. Not cool.

[IDONTOWNAFORD]

I just got a new 2010 sport a few weeks ago and it looks just like turtlejj's pic on both sides. Not cool.

 

You gotta give them a few years to perfect the new model fusions. Come on, stop whining and give F.O.R.D. a chance...they're trying reeeallly hardd!111

[ImBroke]

Mine was perfect when I bought it new. Now, not so much. I was hoping to see others. I did see a new 11 on the lot with the same issue. The others (8) were perfect. Still love the car, but this part sucks.

 

 

[grngt97]

I have the same issue on my vehicle as well, but its drivers side only.

I wonder if the cold weather (from MI here) is making the fascias warp a little?

[djdcz1]

I have the same issue on my vehicle as well, but its drivers side only.

I wonder if the cold weather (from MI here) is making the fascias warp a little?

 

It seems to be a missing or loose bolt. I tried locating the bolts for that fender connection, but can't find them. Probably need to take off some parts to get at. I'm going to bring it to the attention of the dealer, next time I'm in for maintenance.

 

If anyone else has the dealer look at it, please post the results.

[turtlejj]

It seems to be a missing or loose bolt. I tried locating the bolts for that fender connection, but can't find them. Probably need to take off some parts to get at. I'm going to bring it to the attention of the dealer, next time I'm in for maintenance.

 

If anyone else has the dealer look at it, please post the results.

 

Looked into this a bit while the left-front tire was off for rotation the other day. I pulled the fender liner off to look for something obvious and easy to correct. Well, no such luck of course. There aren't any easily accessible fasteners that would tighten the gap. Perhaps the headlight assembly has to come out but I wasn't going there.

[djdcz1]

Looked into this a bit while the left-front tire was off for rotation the other day. I pulled the fender liner off to look for something obvious and easy to correct. Well, no such luck of course. There aren't any easily accessible fasteners that would tighten the gap. Perhaps the headlight assembly has to come out but I wasn't going there.

 

Turtlejj, thanks for the info.

 

Seems like it's going to be very difficult to access.

[dabige]

I noticed a similar situation on my Fusion as well. :banghead: Like a couple others, it's only on the driver's side. On the passenger side, where the bumper fascia meets the wheel well, it's actually bowed slightly inward.

 

In any case, I don't think it's completely a fastener issue, it's a material issue, (aka cheaper plastic). Note that these variances are happening where the metal body panel meets plastic. It's also a spot where unsupported/unrestrained plastic comes to a point/sharp outside corner...a very easy place for plastic to deform unless it's substantially reinforced. Metal will hold its shape much better than most plastics and it will also expand and contract differently than plastic. Looking all over those seams in the front bumper fascia, there are many irregularities between the two materials. It could be anything from inferior plastic used for the panel, slight jarrings of the panel after the initial molding process (moving it before it cools completely), expansion and contraction of the materials from ambient temperature, or some combination of all of the above. Look at the seam between the rear bumper fascia and the metal rear panels; you'll find similar irregularities there as well...even between the taillights and the fascia seam.

 

Either way, Ford has never been know for superb fit-and-finish.

Edited January 25, 2011 by dabige

[gb_fusionguy]

I noticed a similar situation on my Fusion as well. :banghead: Like a couple others, it's only on the driver's side. On the passenger side, where the bumper fascia meets the wheel well, it's actually bowed slightly inward.

 

In any case, I don't think it's completely a fastener issue, it's a material issue, (aka cheaper plastic). Note that these variances are happening where the metal body panel meets plastic. It's also a spot where unsupported/unrestrained plastic comes to a point/sharp outside corner...a very easy place for plastic to deform unless it's substantially reinforced. Metal will hold its shape much better than most plastics and it will also expand and contract differently than plastic. Looking all over those seams in the front bumper fascia, there are many irregularities between the two materials. It could be anything from inferior plastic used for the panel, slight jarrings of the panel after the initial molding process (moving it before it cools completely), expansion and contraction of the materials from ambient temperature, or some combination of all of the above. Look at the seam between the rear bumper fascia and the metal rear panels; you'll find similar irregularities there as well...even between the taillights and the fascia seam.

 

Either way, Ford has never been know for superb fit-and-finish.

 

Well, just checked my 2011 sport, and I got to say, they are flawless. Tight seams all around. Not sure what the born date was, but just picked it up from the dealer on Thursday. Really very happy with the fit and finish on this one. Much better than the 2008 SE I had.

 

GB

[dabige]

Ok, so I had a little more time to check out the fascia seam. My neighbor's Fusion (also a 2010), has the same issue to the same extent as mine. I still stand behind my original theories, but I have some more to add to it now. Upon popping the hood, as far as I can see, there are two ways to access where this fascia panel attaches to the rest of the car:

1. Remove the offending side(s)' headlight assembly. With the hood open, if you look between the side panel (metal) and the headlight assembly mounts, you can see a couple mounting struts that seem to be where the bumper fascia attaches.
2. Remove the bottom engine cover, and go about the previously stated from underneath. Which method is a bigger PITA? Jury's still out on that one...

I still think it could be cause by what I mentioned in my previous post, but here are a couple more potential variables. The mounting struts may be slightly deformed, which cause the said panel to bow outwards. And/or, as previously mentioned, what looks to be nuts attaching this panel somehow worked loose.

 

As for the issue with the mirror plastic, I noticed a little play in the bottom corner on both of my mirrors as well as my neighbor's Fusion, although neither seemed to be enough play to be of much of any serious concern. My guesses are either, again, cheap/"blemished" (for lack of a better term) plastic or the bolts holding the mirrors to the door were tightened a little too tight (causing the plastic to bow slightly). The latter could also be demonstrated by tightening a switch plate or outlet cover on your wall too tight...too tight and the plastic begins to warp on the outside edges, causing a poor seal between the plate and the wall.

[Snowball 2010]

I noticed the front end doesn't line up correctly with the front fenders. It's more apparent on the driver side.

 

There is a 1/4" gap, drivers side, were the front fender meets the front end. You can see the back of the headlight thru the gap. Also, the front fender sticks out about a 1/8" more then the front end, were they meet.

 

Finally, the passenger side mirror outer shell has a seal going all the way around it and the bottom portion of the outer shell seal doesn't make full contact with the door. The seals purpose is to keep water from getting behind the outer shell. After washing my car I can push on the outer shell, which will make the seal contact the door, and water will come out. The drivers side mirrors outer shell makes good/tight contact with the door.

 

Sorry, If i haven't explained very well, but I'll try to attach some pics of the areas I'm talking about.

 

Plan on taking it to the dealer soon and see what they say.

 

Has anyone else noticed these issues?

 

Hey, sorry to hear about your front fender issue.......NOW I'M PISSED......cause now I know I'm not alone.

I went to my dealer 2 weeks ago to show them this problem, they asked me what was my mileage. I told them around 42,000 K

they answered back your not covered after 20,000K. This problem is caused by Ford's lack of delivering a quality product, the little details like

finishing and adjustments are over looked and are done too fast. When it comes to warranty coverage they will do just about anything not

to pay.........go figure.....they want us to buy domestic but they deliver sub-standard quality.

So...."FORD QUALITY IS JOB NONE" sorry I love my Fusion but I'm very disappointed with Ford and their dealers.