cracking noise

[Guardian_Bob]

I printed up the TSB and went to a dealer (not my dealer) and asked for parts to be ordered. I was told this was not a safety issue and they could not order parts until I, and the shop, verified there was a problem.

 

I have not heard the noise yet, but it bothers me that I have to wait until there is an actual problem to get this fixed. Either there is a design problem or there is not. My car falls within the dates that the TSB applies to.

 

You sure you didn't hear it? Roll down your windows and try again. I could have sworn I heard a ping pong ball drop or something. :victory:

[acdii]

 

You sure you didn't hear it? Roll down your windows and try again. I could have sworn I heard a ping pong ball drop or something. :victory:

Come to think of it, Me too, all the way over here!

[elle]

I took mine in today for that and a few other, minor issues. Will let you all know if the problem gets resolved.

[smr2112]

Others have said they can't really hear it easily, and I am in that boat. Not

sure if I have the issue or not, but I did hear what sounds like there is a stone

in the tire - almost a light "click,click" noise. Have to check to see that I

do/don't have a stone wdged in the tire tread.

 

I can only hear it if I turn off the radio, open the driver window and stick

my head out part way out the window. For those who are certain they

have the issue, does this accurately describe it?

 

Mine just started, I am at 1100 miles and I just noticed. Would not

call it a ping-pong ball sound (how strange!), and could only hear

it next to a wall to reflect the sounds - so may just be starting.

 

I'll have the dealer check it anyway.

Edited June 7, 2013 by smr2112

[Guardian_Bob]

Others have said they can't really hear it easily, and I am in that boat. Not

sure if I have the issue or not, but I did hear what sounds like there is a stone

in the tire - almost a light "click,click" noise. Have to check to see that I

do/don't have a stone wdged in the tire tread.

 

I can only hear it if I turn off the radio, open the driver window and stick

my head out part way out the window. For those who are certain they

have the issue, does this accurately describe it?

 

 

As I said elsewhere and I've heard it described, think a ping pong ball being dropped. That noise.

[elle]

Just an update; my parts are on order for this fix, should take about three weeks. Also, I don't know who else here was having the problems with the trim behind the triangular windows, but apparently those little pieces were re-engineered and there's a new part for that, as well-- also on order. Hope to have it all resolved by early July.

[milleron]

 

I have an appointment at 9 AM tomorrow, so I presume the parts are in. Everyone's information about a back order makes me wonder if they have something else in mind, such as an inspection, which they did not require when they told me they were ordering the thrust washers a week or two ago. Whether or not that's the case, I'll post the results of that service visit.

As suspected, the thrust washers were not in. They told me that their "computer listed them as in." Hence, they called me in, but when I got there they discovered their error. So it appears that they're still on back order, at least here in Ohio.

[milleron]

 

I have not heard the noise yet, but it bothers me that I have to wait until there is an actual problem to get this fixed. Either there is a design problem or there is not. My car falls within the dates that the TSB applies to.

 

I agree with you. The problem is so very common, that they ought to be doing preventive maintenance for those of us who've educated ourselves about the TSB. I've not been assured that waiting until the problem occurs will not cause permanent damage OR that it won't cause problems with other components, such as motor mounts, for example. There's not a uniform national policy, as my dealer is perfectly willing to do this work at my request. It's just that he can't get the thrust washers yet.

[SalvadorAssumpcao]

Others have said they can't really hear it easily, and I am in that boat. Not

sure if I have the issue or not, but I did hear what sounds like there is a stone

in the tire - almost a light "click,click" noise. Have to check to see that I

do/don't have a stone wdged in the tire tread.

 

I can only hear it if I turn off the radio, open the driver window and stick

my head out part way out the window. For those who are certain they

have the issue, does this accurately describe it?

 

.

It describes well what I hear.

Initially, I thought it was a stone in one of the tires, but I haven't found any, yet.

Also, > 90% of the time I heard it, I was either coming to or starting from a stop. Usually clicks once, sometimes a few times in quick succession. I don't think if it was a stone the click would start and stop like that.

 

Car has a little ver 4k miles and I only started hearing the click in the last few weeks. But it could well be there before. Weather is warming up so I've been driving with windows at least partially down most of the time. With windows up and/or any significant road noise, I don't think it can be heard.

[hybridbear]

Others have said they can't really hear it easily, and I am in that boat. Not

sure if I have the issue or not, but I did hear what sounds like there is a stone

in the tire - almost a light "click,click" noise. Have to check to see that I

do/don't have a stone wdged in the tire tread.

 

I can only hear it if I turn off the radio, open the driver window and stick

my head out part way out the window. For those who are certain they

have the issue, does this accurately describe it?

 

Mine just started, I am at 1100 miles and I just noticed. Would not

call it a ping-pong ball sound (how strange!), and could only hear

it next to a wall to reflect the sounds - so may just be starting.

 

I'll have the dealer check it anyway.

It describes well what I hear.

Initially, I thought it was a stone in one of the tires, but I haven't found any, yet.

Also, > 90% of the time I heard it, I was either coming to or starting from a stop. Usually clicks once, sometimes a few times in quick succession. I don't think if it was a stone the click would start and stop like that.

 

Car has a little ver 4k miles and I only started hearing the click in the last few weeks. But it could well be there before. Weather is warming up so I've been driving with windows at least partially down most of the time. With windows up and/or any significant road noise, I don't think it can be heard.

I hear a noise that sounds like a stone in a tire, not every time taking off or slowing down but quite often. Up to this point I have just assumed that it is a stone in the tire tread. I guess I'll need to pay more attention now and see

[neod192]

Also, I don't know who else here was having the problems with the trim behind the triangular windows, but apparently those little pieces were re-engineered and there's a new part for that, as well-- also on order. Hope to have it all resolved by early July.

That was me! They fixed it by taking that area apart and re-setting all the trim pieces - they didn't replace it with a re-engineered part - and it seems to be fine.

[smr2112]

If we are talking about the same black trapazoidal piece, it's a piece of inset plastic that is directly behind the triangle

window. Between it and the regular window - about 1.5-2" wide, 5" tall.

 

It pops out part of the way, I push it back in flush and it's fine for a while. I am taking my car in on

Saturday for this and the cracking TSB.

 

Is there anything I can tell them about the re-engineered piece, is there anything specific, or TSB

I can point to? Likely that piece will be fine when I go in and they'll do nothing without pointing at

the TSB like for the cracking.

[gkinla]

Good news, I received an email from my service advisor this morning telling me that all the parts were in stock. I'm at the dealer getting the washers installed. I'll post what my first impression is and follow up after getting some time and miles on my FFH.

[gkinla]

Okay, the TSB 13-5-24 is done. On my drive home I drove through quiet streets with air and radio off, windows down. It was very quiet and seemed smoother (probably wishful thinking). No noise and I really tried to repeat the conditions I'm so used to hearing. I'll report back in a few weeks after getting some miles on the car.

[Trey Bartsch]

I have a 2013 Fusion Hybrid which I purchased just before Christmas. Around the 4k I began hearing this same noise and took it in to my local dealer here in Houston. I had no idea how long this process would take. I've taken my fusion in 4 times since April as the dealer tried replacing different parts to fix the problem with obviously no luck before I found the TSB on here back in mid-may and provided it to them. Since about May 20th, the expected date of the washers arriving has been 2 days...6 days...2 weeks...1 month. Finally, last week they notified me that they have them. I took my car in on Wednesday for what they explained should only take an hour or so to replace, and here I am on Sunday with my car still in the shop. They explained that they ordered the incorrect washers and the correct ones will be here Monday. At this point, I don't know what to think. But I do know that I'm tired of driving this Focus rental and can't wait to get back in my Fusion...ping-pong/crack noise free!

 

Thanks everyone for posting their updates. If I hadn't found the TSB on here, I'd probably still be waiting around for the dealer to figure it out.

[hermans]

I don't know how the dealer could have ordered the wrong parts as the correct part numbers are on the TSB. Mine was fixed a few weeks ago and the snap-crackle-pop has not returned.

 

Here's what your dealer should have ordered:

 

DG9Z-7G273-B Thrust Washer

W713640-S437 Halfshaft Nut

W500545-S439 Ball Joint Bolt

W520214-S442 Ball Joint Nut

Edited June 30, 2013 by hermans

[Dan Newman]

Parts installed today; noises completely gone. Hope they stay away...

[topguy150]

You have a recent build, mine is a Dec 2012 build noise started at about 500 miles and seems to be getting worse, hearing now when I slow down to about 10 mph, and always when I start to accelerate either in EV or ICE... annoying especially with a price tag at 36k...

 

My dealer replaced the hybrid cooling pump, noise stopped....dealer was surprise and so was i, no noise since.

[milleron]

My dealer replaced the hybrid cooling pump, noise stopped....dealer was surprise and so was i, no noise since.

 

Interesting. At 1,850 miles I've not been aware of the noise. However, the third day I had the car, I got an idiot light informing me that there was a "powertrain fault." I took it to the dealer, and they determined that there was just some water in the wiring of the sensor monitoring the hybrid cooling pump. A few days later, the light returned, and they had to replace the hybrid cooling pump (car was in the shop for 4 days for that). Two could be coincidence, but hearing about two of these pumps failing SO early in the life of the car -- mine was virtually immediate -- can't do anything but raise suspicions about a manufacturing defect in that part.

[elle]

I'm quite certain that not everyone in this thread is hearing the same noise. Pumps in hybrids make noise that is unusual to those who haven't driven a hybrid before.

[Diana Fis]

I am a new member to this forum. Just signed up today. I just took my 2013 FFH to the dealer on July 2nd to have a list of things repaired, and one of the things being a ping pong noise. It's funny that I called it a ping pong noise not knowing that first there was a forum and others called it the same thing. At first I got the "we can replicate it" from the service center and then I asked them "did you test drive the car, because I can replicate it in one minute of driving". I took them on the test drive and because I insisted they actually did some research and found the TSB. They ordered the parts but as many of you have found the parts are in back order. They could not give me a date as to when they would come in. I wish I would of found this forum before but regardless the TSB was found. I have other issues with my car that I will be posting in a different thread to see if others are having the same problems. Thanks for all of the good information so far.

[Diana Fis]

Hello all,

 

I've attached the sound of my FFH pulling out of my garage and popping. It's pretty loud and I can hear it even over the radio.

 

-Harbor

In the background I hear that winding noise along with the ping pong noise is that winding noise normal for a hybrid?

[reddog]

Good news. dealership ordered the following parts and it seemed to fix the cracking and popping sound. I'm keeping my fingers crossed.

DG9Z*3B436*E

[reddog]

Good news. dealership ordered the following parts and it seemed to fix the cracking and popping sound. I'm keeping my fingers crossed.

DG9Z*3B436*E

Oops! spoke too soon. A few days after they replaced parts the popping and cracking noise is back. Just sent a message to dealership to see what is the next solution.

[neod192]

Oops! spoke too soon. A few days after they replaced parts the popping and cracking noise is back. Just sent a message to dealership to see what is the next solution.

Did they do both sides? I think the dealer has the option of doing just one side or both. My dealer called me yesterday to let me know the parts are in and it sounds like they only got one set of parts .. I asked them to order another set for the other side - not sure which side makes the sound, but I want both sides fixed.