cracking noise

[Riggo]

Which would end up being worse, bad cv stub or bad motor mounts? I really hope they come up with a fix soon. Picking up my car this weekend and not looking forward to the first time I start hearing these noises.

[GrySql]

Which would end up being worse, bad cv stub or bad motor mounts? I really hope they come up with a fix soon. Picking up my car this weekend and not looking forward to the first time I start hearing these noises.

Riggo,

Remember that this is a small slice of what customers are reporting, your car is a new build and hopefully this, and other reported problems were sorted out before you take delivery.

This Forum is an active group and has been most effective in bringing these new model FFH cars little foibles under scrutiny.

In the larger picture, just consider how much better informed you are than those of us that bought the earliest models, it's a good thing.

Check your car over real well, drive it and if it meets your approval take it home and begin enjoying what we, for the most part, are enjoying - it's a nice car. :)

[CombsAuthor]

Riggo,

Remember that this is a small slice of what customers are reporting, your car is a new build and hopefully this, and other reported problems were sorted out before you take delivery.

This Forum is an active group and has been most effective in bringing these new model FFH cars little foibles under scrutiny.

In the larger picture, just consider how much better informed you are than those of us that bought the earliest models, it's a good thing.

Check your car over real well, drive it and if it meets your approval take it home and begin enjoying what we, for the most part, are enjoying - it's a nice car. :)

Great post GrySql

[lmp180psu]

Riggo,

Remember that this is a small slice of what customers are reporting, your car is a new build and hopefully this, and other reported problems were sorted out before you take delivery.

This Forum is an active group and has been most effective in bringing these new model FFH cars little foibles under scrutiny.

In the larger picture, just consider how much better informed you are than those of us that bought the earliest models, it's a good thing.

Check your car over real well, drive it and if it meets your approval take it home and begin enjoying what we, for the most part, are enjoying - it's a nice car. :)

Agree with all points and for the most part we are all enjoying our cars. My one thought though is, if there this isnt an issue with new builds, why hasn't a TSB been produced for existing cars? I hope Riggo doesn't have this issue, but without a fix out there, it COULD occur.

[GrySql]

but without a fix out there, it COULD occur.

Post 124 has a Dealer fix that looks promising, "he said they have adjusted (torqued) some suspension parts and the noise is gone."

That would be nice.

 

Even getting a 'Customer Satisfaction' bulletin through channels at Ford takes over 90 days.

For example, the 505A gear shift knob, I know exactly when Ford corporate first knew about it, and the bulletin hit the Dealers over 6 weeks later.

If we go back in this thread to when Ford Engineering first admitted knowledge of this 'cracking' sound I'll bet there will be a Dealer bulletin released within that time frame.

(Post 20, March 27, 2013)

It's not the way we'd want it but it is the way it is, it's a huge operation.

Edited April 17, 2013 by GrySql

[acdii]

Which would end up being worse, bad cv stub or bad motor mounts? I really hope they come up with a fix soon. Picking up my car this weekend and not looking forward to the first time I start hearing these noises.

CV is worse as it can leave you stranded. Loose motor mount not so much, it will get worse over time, but it wont leave you stranded when it breaks. The fact that one person posted the tightened some parts, leaves me optimistic that it is a loose component and not an axle.

[dmt1971]

Picked up my car this afternoon. So far the noise is gone (about 15 minutes of stop and go driving). Hopefully it will stay that way! Here's what they did:

 

"Lift car and inspect. Tighten all front suspension bolts, torque link and axle shaft nuts. Test drive."

 

Anyone else get theirs fixed yet?

[GrySql]

Picked up my car this afternoon. So far the noise is gone (about 15 minutes of stop and go driving). Hopefully it will stay that way! Here's what they did:

 

"Lift car and inspect. Tighten all front suspension bolts, torque link and axle shaft nuts. Test drive."

 

Anyone else get theirs fixed yet?

Great, I'll be relaying all this info to my Dealer tomorrow - thank you!

[rvlasek]

Picked up my car this afternoon. So far the noise is gone (about 15 minutes of stop and go driving). Hopefully it will stay that way! Here's what they did:

 

"Lift car and inspect. Tighten all front suspension bolts, torque link and axle shaft nuts. Test drive."

 

Anyone else get theirs fixed yet?

OK< Thanks,,,keep us informed if noise stays away , planning on showing the remedy to my dealer in about a week or so to have this work done.., have shifter replaced at same time... thanks again, hope it works....

[JSKershaw]

I like the fact that they don't have to take the car apart to fix. If all it needs is tightening or adjusting that sounds promising! I will be sure to mention this to the dealer when I take my car in to change the gear shifter.

[GrySql]

I'm at my dealer now, they tell me the tightening the front end bolts, grease, struts & CV's haven't been long term fixes.

I gave them the Hotline number from this thread and my Rep is on the phone.

My car is on the rack right now being inspected.

We'll see

 

At least they provided another free lunch while we wait. ;0)

[rvlasek]

OK, let us know it corrects cracklin issue, if it works I will go in next week for fix...any detail on exact work would be great to make sure my dealer gets it right...

[reddog]

I just wanted to be another concerned owner of the 2013 fusion hybrid. Popping, cracking and clicking sounds started about four to six weeks ago. Took it to the dealership to fix and the responses on this forum sounds very similar. Torqued a couple components, changed pads, etc. They had for two days and little to no change. Not happy. Hope the ford mothership is hearing this!

[GrySql]

Just returned from my Dealer. No joy in repairing this issue.

We are still at the same point as when this Topic was started, no known repair for this 'cracking, popping, tinging' sound.

 

They inspected the car, everything was torqued properly, nothing 'looked' wrong.

This Dealer has tried to repair 3 of these Fusions and has not been successful, all have returned with the same noises after a week or two.

Currently they have done pads, struts, CV assemblies, re-torquing and re-greasing all to no avail - the Service Department is not happy.

 

Today, after using the Ford Hotline, they told me that Ford Engineering is still in the dark about a fix.

The Dealer was instructed to not do any other repair attempts at this time (as we already knew).

I'll be notified as soon as my Dealer Rep has any new info, I'll also call him every week just in case.

 

I'd be surprised if some Forum member here doesn't know before the Dealers know.

My Dealer Rep took this website's URL so he could read what we are finding and doing on this Topic, he is amazed (and pleased) at the info I had to show him.

 

Edit:

BTW, the CV axle assemblies are on 'back order' and not valuable for at least a week, or more - so sayeth my Dealer.

Edited April 19, 2013 by GrySql

[rvlasek]

Thanks for info.... Sounds like the response from Dealer that they had tried to repair three others with same noise problem with no good results, that this is a very wide spread problem in Fusion Hybrid 2013, hope they put their best engineers on this....becoming more annoyed at noise in such a hi-tech new car...

Edited April 19, 2013 by rvlasek

[dmt1971]

Picked up my car this afternoon. So far the noise is gone (about 15 minutes of stop and go driving). Hopefully it will stay that way! Here's what they did:

 

"Lift car and inspect. Tighten all front suspension bolts, torque link and axle shaft nuts. Test drive."

 

Anyone else get theirs fixed yet?

Still nice and quiet today. Hopefully the noise will not come back in a week. Also got my leather shift knob. Much nicer. "Recall" letter came today for the shift knob . . .

[GrySql]

My Dealer Rep called back this morning stating that the Ford Hotline had sent them a message regarding my 'cracking' noise.

Ford Hotline engineering wanted me to bring the car back in and have the front brake rotors re-surfaced to see if that helped - I laughed.

My reply was to the effect that I would accept new parts to my car but not to experiment with existing parts, the Rep agreed with me.

He has another '13 FFH there, close by, that they are doing things to, piece by piece - I will be kept advised.

 

I brought up the idea of them checking the motor mounts (as mentioned in this Topic) instead of concentrating on rolling parts.

This noise is more a 'torque' sound that a repetitious cyclic sound.

That idea had not been thought of by their mechanics and will now be looked in to.

 

I also expressed my displeasure that Ford Engineering is having Dealers experiment with customers cars, at the customers inconvenience.

He agreed, I will be kept informed of any progress.

[acdii]

 

That idea had not been thought of by their mechanics and will now be looked in to.

 

Seriously? somehow I am not surprised though.

[GrySql]

Seriously? somehow I am not surprised though.

This Forum is composed of people from many walks of life, not just motor-heads.

I see a very wide degree of thought displayed here that in the closed loop of engineering or mechanical thinking may be more 'outside the box' than the garage mentality.

I am not disparaging the hard working mechanics or engineers, bless them all, but this Forum group is inquisitive in areas that a paid Ford committee may not be.

 

I'm happy to be a part of such an well rounded group of polite and intelligent people (with one or two oddballs, we know who we are...). ;)

When Ford executives, Ford dealer service experts and other hybrid groups are reading this Forum for insight you know they are getting a good show.

Edited April 19, 2013 by GrySql

[47Minutes]

I'm going to add my Energi to this list. Dropped off at the dealer yesterday for a "popping" sound when the vehicle would start to roll and just before coming to a complete stop. Service rep just called me to say they've traced it to the axle and wanted the car over the weekend to order parts and work on it early next week. I shared with him this thread and the Hotline Assistance number. We'll see if he follows up on that or decides to disregard and start throwing parts at it.

 

I don't remember at what mileage I first noticed it, but I would swear it has been since week 1. I picked it up on 3/28 and have around 1060 miles now.

[acdii]

My problem is these Ford "techs" arent really mechanics anymore, just script monkeys who do what Ford tells them to do. Old school troubleshooting has gone the way of the DoDo these days. They run across a problem like this and first thing they do is IM Ford. The "tech" in the other end of the IM looks it up on his troubleshooting check list and responds back, do this, "tech working on the car does this, comes back and say, this didnt work, "tech" on the other end say, Oh well, cant help you.

 

Now a real mechanic would get the car, take it for a test drive, identify the noise of said complaint and try to reproduce the noise on the lift. Hmm noise cant be heard on the lift? Well, then noise must be generated under load. OK, have helper get in car, set parking brake, block wheels, stand on the brake and put it in gear. Listen for noise while under stress, hear noise? Now trace the noise with helper in car.

 

Thats how I used to troubleshoot these when I was a mechanic, note I was a "mechanic" not a "tech". A mechanic can figure this crap out without a book or IM chat to some dude clear across the country who has no insight on the actual vehicle. Describe the sound, you know, it sounds like this,.......

 

If I had the means and equipment to figure out what was wrong with the one I had, I would have done so and told Ford to screw themselves. My faith in their "techs" is about on par with those "techs" used for troubleshooting a PC, not very high. Especially when the evidence is right in front of their eyes, and they totally ignore the facts and rely on virtual reality IE the dash readouts. The Dash says its getting this, yet the REAL fill is actually this. Yeah, faith is lowwwww.

[47Minutes]

I've just had my issue escalated to a Ford Customer Service Manager. I was told to expect to hear from the CSM after they've reviewed the case and spoken to the dealership. (likely Monday)

 

I'll share updates as this progresses.

[rvlasek]

Thanks for info....sounds like noise issue is widespread Fusion Hybrid/Energi vehicles...

[GrySql]

My problem is these Ford "techs" arent really mechanics anymore, just script monkeys who do what Ford tells them to do.

Most companies appreciate it when their employees follow their policies, nothing to rant about there.

You've also painted a very large segment of hardworking men and women as inept and incompetent, a bit harsh I think.

Sure, there are folks doing jobs all over that are not as good at it as one may like but there are also many more working and getting 'Cert's' for their walls so they can improve.

You have to start somewhere.

 

In my first attempt for service to my FFH I came into contact with both types, unfortunately the employee that needed improvement was in management.

The hard working 'script monkey' (as you put it) was overruled and could have solved my problem at that time, I feel for him in that type of local toxic supervision environment.

I now have a very good team working for and with me, they are dealing with a lot of new technology with these cars and are coming up to speed as fast as they can.

I've talked with a lot of them, from the top service management to the guy putting the tire on my spare tire.

This is a very large operation, with a 60-bay Service Department but alas, they all work for Ford and must follow certain guidelines.

You are correct, they need to interact with the famous 'Hotline' but still have a lot of leeway in helping their customers.

 

We've heard of the Dealers that put various parts in the FFH's but the problem persists.

My Dealer is willing to listen and try different approaches but not willing to do the same thing over and over if it doesn't work, makes sense to me.

Having said that, they also MUST tell me what the Hotline offers as a repair, as unlikely as it may sound.

There is even some talk of the actual parts themselves not meeting spec, like 47Minutes brand new Energi with the same problem. Bad CV assemblies, transmission mounts or strut bushings from the international suppliers?

 

I'm a concerned customer regarding this issue and have been reassured that this is not a safety issue.

There are a lot of good people working on this and the fix will come soon, I'm sure.

Meanwhile, I'll continue to enjoy my car.

[Harbor]

I have to believe the reponse depends on the dealership.

 

The ones that are just trying to solve customer issues will have more latitude. The ones that are watching the every penny won't make a move without being reimbursed by corporate. In those cases, acdii is correct and I can see why he says they follow the script. My dealership in NH won't make a move without corporate authorization. They tell me not to even bother with an appointment until they know what the solution is (and invariably how they're getting paid). I'm not passing judgement here; just stating that we might see different responses depending on the dealership.

 

The ability of the technicians is secondary to the business model. They might be awesome but not given authority to solve it on their own.

 

-Harbor

Edited April 21, 2013 by Harbor