2006 Ford Fusion SEL 3.0L V6 from North America
Maybe other Fusions were made better, but the dealer's and Ford's lack of services is unacceptable
Climate control problems - several resistors replaced.
AC doors make loud noises when turning AC on/off, checked several times by the dealership and said to be normal.
Power window switches - 3/4 replaced due to intermittency.
Front brakes replaced at 5000 km, rear brakes replaced at 8000 km, front and back machined at 17000 km and only then did the car finally start to brake properly.
Blower motor replaced at 33000.
Engine making higher pitched ticking sound, dealership says they cannot trace the problem and to not worry about it since I am leasing the car.
For all the problems I have had, even though none have been life threatening, I am disappointed in this car.
No new car owner should have to go through this.
Dealerships should also do more to help customers who have bought troublesome cars, but the dealer says Ford won't let them replace anything 'til it's absolutely toast, a testament to the company's finances (?)
Would you buy another car from this manufacturer? No
Review Date: 12th October, 2008
Try another dealer; it seems that this dealer doesn't want to work on this car, especially since it's under the warranty. You won't have to pay for it, but I would first try another Ford dealer.
You need to heed the advice of the previous commenter and seek out another dealer. There are HUGE differences in dealerships. I wouldn't take a pair of roller skates to the dealer I bought my Fusion from. I drive 15 miles further to get my warranty oil changes and service done. The dealer I use has been very good. Of course I haven't had any problems with my 2006 Fusion so I can't say how good the repairs might be. Ford DOES have a reputation for HORRIBLE service, but since their cars (the ones I've owned at least) have been flawless, I've never had to rely on them for any repairs.
Yes, the AC noise you are talking about must be normal, because I have read other reviews that experienced the same thing. Plus, my Fusion SE is a 2008 and does the same thing... however, given I live in 100 degree weather almost everyday during spring and summer here in Oklahoma, it is not often that I have to turn off the AC...
My 2009 MKZ doesn't make any unexpected noises at all when turning on and off the air conditioner, and I do that frequently, like five or six times a day. Maybe they fixed that. I expect the MKZ and Fusion air conditioners are identical although I don't really know.
The one funny thing I experienced when the car was brand new in the winter was a loud thump when first starting the car at 30 degrees F, turning on the heat and changing the heater settings. I think it was a heater door sticking before it opened or closed. It really startled me the first time it happened, but now I just think of it as the car's personality. Never happens in warmer weather, and also it got quieter after the first few months of use.
We have both an MKZ and a Fusion and I have never noticed this noise. However, we live in the Sunbelt and seldom see temperatures below 30 degrees. I think your very good deduction is probably the answer, as I DID experience this noise on another car rarely and it was exactly what you suggested: a flow door sticking a little and then jolting open.