2010 Fusion Sport AWD Rotational sound btwn 38-42mph - FordFusionClub.com : The #1 Ford Fusion Forum
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post #1 of 41 (permalink) Old 11-25-2009, 10:23 PM Thread Starter
Bicycle Rider
 
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2010 Fusion Sport AWD Rotational sound btwn 38-42mph

Experience rotational sound that sounds like driving over grooved section of the highway. Except this occurs when driving at slower speeds and on smooth pavement.

I am scheduled to bring in for warranty service, but wanted to see if anyone else has experienced anything similar.
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post #2 of 41 (permalink) Old 11-25-2009, 11:21 PM
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Re: 2010 Fusion Sport AWD Rotational sound btwn 38-42mph

Oh yeah! There is an entire thread on this subject. No one seems to be able to find a cause or solution. Let us know if your dealer has any ideas.

2010 Fusion Sport AWD in Sangria Red w/Sport Red Accent- Steeda STB, Hood struts
2002 Thunderbird in Thunderbird Blue- Borla exhaust, custom CAI, SCT tune
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post #3 of 41 (permalink) Old 12-29-2009, 08:00 PM
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Re: 2010 Fusion Sport AWD Rotational sound btwn 38-42mph

I'll keep looking for the threads on this one, but I experience it with my 2010 Fusion Sport AWD. It usually happens around 40mph, and from what I can tell, it's when it shifts into 5th gear during a "leisurely" acceleration. If I'm doing a hard acceleration, the shift to 5th gear is at a higher speed, and I don't hear this sound.

I'm wondering what it is...
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post #4 of 41 (permalink) Old 12-29-2009, 08:16 PM
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Re: 2010 Fusion Sport AWD Rotational sound btwn 38-42mph

Does anyone know where the "whole thread on this thing" is located? I just did some searching and couldn't find anything on it.
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post #5 of 41 (permalink) Old 12-30-2009, 02:55 PM
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Re: 2010 Fusion Sport AWD Rotational sound btwn 38-42mph

My wife's 2008 Edge AWD just had the same problem, which our dealership correctly diagnosed as a bad rear-wheel bearing...

Have them look at the rear wheel bearings for abnormal wear or lack of lubricant.

2010 Sangria Red Sport AWD, package 402a. MPT 93 Oct tune, customized. F35R Gen2 intake from Enstar Performance. 5000K HIDs. LED Taillights. Switchbacks front signals. Stripe kit in a box in the garage; lowering springs, and trans mount coming soon...
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post #6 of 41 (permalink) Old 12-30-2009, 04:12 PM
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Re: 2010 Fusion Sport AWD Rotational sound btwn 38-42mph

VERY goof to know! I will have to look for that when the car I ordered arrives.
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post #7 of 41 (permalink) Old 01-23-2010, 11:29 AM Thread Starter
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Re: 2010 Fusion Sport AWD Rotational sound btwn 38-42mph

Update from Ford Dealership after Two visits to determine what is causing the Rotational sound between 38-42 mph - Ford Tech heard the "Drown" type sound on the right side of the vehicle. He eliminate the wheel bearings that was similar to the Ford Edge 2008 response saying that eliminated the similar problem. The sound was only heard under normal load and driving through this speed normal steady accelerating to 50 mph. Heavy acceleration or if you were going down hill and coasted you did not hear the "Drown" sound. Finally, after using several small micro phones to eliminate any road noises, the Ford Tech identified the Torque Converter was LOCKING UP between the 38 to 42 MPH. It was at 100% LOCK UP and should only be 40 to 50% LOCK UP in that speed range. I have an APPOINTMENT ON JAN 26TH AT FORD DEALERSHIP TO REPLACE THE TORQUE CONVERTER. I will give an update after the repair has been made.
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post #8 of 41 (permalink) Old 01-24-2010, 10:55 AM
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Re: 2010 Fusion Sport AWD Rotational sound btwn 38-42mph

Sounds like Ford is serious about deploying necessary tech resources to drill down to the root cause of your problem. I am impressed. Many other car manufacturers are arrogant, claiming their cars cant have defects, and wont listen to their customers and neither support them.

2007 Fusion SEL V6 AWD gone)
2002 Miata supercharged
2010 Taurus SEL
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post #9 of 41 (permalink) Old 01-27-2010, 01:33 AM
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Re: 2010 Fusion Sport AWD Rotational sound btwn 38-42mph

Glad to hear you are being taken care of... if you look in this thread, I also had a problem with my torque converter... I had different issues but the same part. I was told that Ford's supplier for the plates within the converter had messed up and didn't find the issue until after install. I expect more posts about stuff like this. After a few days though, the dealer replaced my converter and re-flashed the computer and I was good to go! Good luck!
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post #10 of 41 (permalink) Old 02-06-2010, 07:26 PM Thread Starter
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Re: 2010 Fusion Sport AWD Rotational sound btwn 38-42mph

Ford Fusion AWD Sport Update from Ford Dealer: Torque Convert was replaced, but it did not eliminate the "Thread Noise" between 38 to 42 MPH. However, the dealer said the Torque Convert was engaging too soon and did not like the way it was operating. They kept the car for three more days and after disconnecting the wires to the Rear Controllers for the AWD the "Thread Noise' went away. I had to wait about a day for the Ford Tech Center to give the OK and Ford approved and ordered the entire Rear End 'one piece' from the Ford Supplier. It has taken just over a week for the part to be Dropped shipped on February 8th. Hope to have my car back by Wednesday or Thursday (Feb 11th) this coming week. The dealer was not sure if the part will arrive Monday or be Shipped from the Ford Supplier, so it may take until Thursday to get it back.

Ford did update my SYNC with two new software upgrades, as there were problems with some of the new Verizon cell phones not syncing up.

I'm really impressed that the Ford Dealer gave me another Ford to drive, as I did not want to drive my car without the controllers working, which would only give me front wheel drive. Keep you posted.
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