cracking noise

[Woodgrain]

I hear this, too. My two cents:

 

It's probably relays. Relays are electro-mechanical switches used to route electricity around the electric part of the powertrain, and likely are quite active in the transitions described. Given the voltage and current necessary to propel a 3,600 vehicle, they have to open and close with some violence to minimize arcing, which would eat away the contact surfaces and make them unreliable.

 

Relays can be quite loud; these are not. In fact, the only reason they are audible at all is becase the FFH is so incredibly quiet.

[GrySql]

It's probably relays.

Relays can be quite loud; these are not.

Not ever owning a hybrid before all these strange noises are new to me.

Mine has done this from day one, nothing has changed in 5400 miles. It is consistent with acceleration and deceleration at very low speeds.

I don't hear shock strut noise going over bumps or at any other time the struts are compressing or rebounding.

It has always sounded like arcing or relay noise to me too, not that I'm an expert.

The behind the grille shutters closing on start-up are a more annoying noise, especially with the FFH's silent start system.

 

I have a Ford Corporate case # and will check back in the Dealer Service Mgr in a month... will post results of follow up...

That is good to hear, a lot of us will be following your story. Thanks.

Edited March 31, 2013 by GrySql

[lolder]

There aren't any relays closing while you're driving, only when you start the car.

[GrySql]

There aren't any relays closing while you're driving, only when you start the car.

Okay :)

Let's go with the brake shim springs....

I'm game.

It's a consistent sound though, I was pointing it out to my wife the other day after reading this thread, she clearly hears it and that is something.

The car drives fine, it's just a box of Rice Krispies.

[rvlasek]

Sounds logical, we know its not the front strut or strut bearings, they changed mine and noise persisted, then they contacted Ford service hotline, and they said known problem, and issued case #. so brake shim could be issue,

[expresspotato]

I hear this, too. My two cents:

 

It's probably relays. Relays are electro-mechanical switches used to route electricity around the electric part of the powertrain, and likely are quite active in the transitions described. Given the voltage and current necessary to propel a 3,600 vehicle, they have to open and close with some violence to minimize arcing, which would eat away the contact surfaces and make them unreliable.

 

Relays can be quite loud; these are not. In fact, the only reason they are audible at all is becase the FFH is so incredibly quiet.

Its not relays not sure where you're getting that idea from.

[BatCat]

Mine is still very quiet after 1400 miles. I like it more everyday. The only thing I am still getting used to are the friction brakes grab when I have to use them, such as in reverse.

[hybridbear]

We have a clunk in the steering when reversing, turning right and applying the brakes gently. One dealer claimed it is the brake pads shifting around. It only happens at low speeds where there is no regen braking, only in reverse and only when turning the wheel right hand down. The clunk is rather loud and can be felt in the steering wheel.

 

The sound of the grille shutters moving is quite annoying too with the silent start as they are rather noisy

[acdii]

I never heard the grill shutters on mine. What do they sound like?

[hybridbear]

I never heard the grill shutters on mine. What do they sound like?

 

An electrical buzzing sound

[GrySql]

I never heard the grill shutters on mine. What do they sound like?

Preparation:

• From a cold start.

• Wear protective clothing and appropriate PPE (Personal Protective Equipment) and a flashlight that meets MSHA standards.

* Optional: Depending on the present state of your matrimonial harmony, you may wish to identify an escape route prior to the engine start.

 

Operation:

Now, position yourself in front of the car with the flashlight on, point it at the shutters behind the grille.

Get your wife* to start the car while you're looking at the illuminated shutters.

If your shutters are like mine they will (edit: for clarity) begin opening then return to the closed position within a very short period, 30 seconds or so.

As you watch them in motion there is a buzzing sound produced from the electric motor that activates the shutters.

 

Results:

If you don't hear any noise and the shutters activate properly, then:

A. Hybridbear and my actuation motors are faulty.

B. Your hearing needs testing.

C. Our buzzing sound is coincidental with the shutter activation and we don't know what we're talking about.

D. All of the above.

Edited April 2, 2013 by GrySql

[acdii]

Hmmm mine are closed when the ignition is off. Maybe thats why I dont hear them. At least they were always closed when I looked before putting the cover on the grill.

[GrySql]

Hmmm mine are closed when the ignition is off.

Yes, that's true, but when the engine starts they open and then close, at least mine do. It's quite a noisy racket when you are watching them.

(We're kind of off topic here and I'll opt out. We can start a thread about this if needed)

Edited April 2, 2013 by GrySql

[expresspotato]

The buzzing you hear could be either the AC compressor or the electric hydraulic pump for the brakes. For me - the shutters make virtually no noise. Let's keep this thread to the click clack of what now seems to be a problem the a component with the braking / wheels.

[GrySql]

The buzzing you hear could be either the AC compressor or the electric hydraulic pump for the brakes. For me - the shutters make virtually no noise. Let's keep this thread to the click clack of what now seems to be a problem the a component with the braking / wheels.

Yes, agreed, but I did leave 'answer C' as a possibility.

-

On topic:

If this is indeed the brakes, seems like Ford would be in a major hurry to sort this out, pronto.

From a safety standpoint this is several layers in importance above replacing the gear shift knob.

[rvlasek]

Comments about cracklin noise, from FORD

 

Hotline Assistance Request 106198****

 

Contact Date:

Technician:

P&A Code:

Vehicle:

 

3/27/20132:01:45 PM
jeff moz******

06432

FUSION

VIN: 3FA6POLUXD*******

R. O. Number: 684****

Request Form Details:

Description of Vehicle Concern:

rattle type noise on accelleration from a stop for a brief moment in reverse or forward going straight, turning left or
right. «almost sounds like a bad cv joint))

Diagnostics Performed:

have chassis ears connected & can hear loudly at the right front strut area (lower end of strut housing)

Parts Replaced:

replaced right front strut & strut mount & Concern still present

Technician's Question:

are there any reports of this type of concern on the new fusions???? tempted to install a right side cv axle but then
ill be starting to throw parts at it which is what i dont want to do.

Additional Comments

Comment from: Ford Comment Date: 3/27/2013 2:48:46 PM
Jeff,

The Hotline has seen similar cases of 2013 Fusion Hybrids exhibiting a click, pop, or ting noise from the front axle
shafts on initial acceleration from a stop, changing vehicle directions (forward to reverse or reverse to forward), and
on initial deceleration caused by an axle shaft to bearing clearance issue. If you are able to isolate the source of this
noise to the front steering knuckles using chassis ears, the above condition is likely occurring. If this is the case no
repairs are available for this concern as it is currently under investigation by engineering and OASIS should be
monitored for updates. Note that axle shaft replacement won't correct this concern so they shouldn't be replaced.

Edited April 4, 2013 by rvlasek

[lmp180psu]

Thanks for the detailed info on this issue. My dealer also said that Ford is aware of this, but no fix has been found yet. Unfortunate, but as long as it isn't a safety issue, I guess it is "ok". Still it is annoying given how refined the car is otherwise. I sort of cringe when I hear the noise.

[rvlasek]

Feel same, makes it sound cheap and its annoying...

[acdii]

Yep thats the same noise I hear.

[expresspotato]

I have an appointment with my dealer tomorrow morning at 7AM... Should I even attend knowing this?

[rvlasek]

Expresspotato, if you want you could call service mgr and ask if any progress made on Ford Hotline Assistance Request 106198928, which is the request info I posted.. I have not talked to anyone since March 27th...

 

regards,,,

[expresspotato]

Oh wow so "caused by an axle shaft to bearing clearance issue" could it be the axle shaft or bearings are too small for whatever holds them?

[expresspotato]

Either way its at the dealer... Will report back EOD hopefully I don't have to keep my rental too long @ $35/day.

[acdii]

Rental? ouch, luckily my dealer provides a loaner if one is available, and usually there will be when I make an appointment.

[expresspotato]

Well dealer claims its the brakes and are ordering new pads... We'll see come Tuesday when they arrive.