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#1 Malc65

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Posted 20 November 2008 - 02:54 PM

I have a Fusion 2 '05 plate 1.4 petrol and have terrible rattles, especially on rough roads (everywhere round here!). They are coming from behind the dashboard, seems to be under where the windscreen heater vents are situated. I have removed the instrument cluster a couple of times but the dashboard seems to be a moulded unit with no access. Have looked under the steering wheel and also removed the glove box on the opposite side searching for obvious loose items but all seems tight. I am nearing the point when I think I shall have to remove the dashboard but cannot find a Haynes manual. Can anyone help?

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#2 mintalkin

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Posted 20 November 2008 - 04:51 PM

ford have a tsb on this subject concerning the lack of padding around the ventilation pipes where they come through the bulkhead from the engine so try and check if you can and add some foam padding.

#3 Malc65

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Posted 20 November 2008 - 07:29 PM

ford have a tsb on this subject concerning the lack of padding around the ventilation pipes where they come through the bulkhead from the engine so try and check if you can and add some foam padding.


Many thanks for that. I will check it out. I cannot find any Ford TSB's on the web but I am still looking.

Thanks again
Malc65

#4 Malc65

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Posted 23 November 2008 - 04:37 PM

ford have a tsb on this subject concerning the lack of padding around the ventilation pipes where they come through the bulkhead from the engine so try and check if you can and add some foam padding.


I removed all the plastic covers from the bulhead at the rear of the engine but the ventilation pipes are well padded and tight. I did find a broken plastic moulding which holds the gauze filter to the heater intake so I replaced it. However the dashboard rattle is still there so I would be grateful if anyone has any further suggestions.

#5 confusion

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Posted 11 January 2009 - 08:57 PM

I removed all the plastic covers from the bulhead at the rear of the engine but the ventilation pipes are well padded and tight. I did find a broken plastic moulding which holds the gauze filter to the heater intake so I replaced it. However the dashboard rattle is still there so I would be grateful if anyone has any further suggestions.

Hi im new to this site as well,and along with the sound of metal sliding about i have the same problem as you a rattle from the passenger side dashboard that's driving me mad,Ive shoved a piece of foam between the windscreen and dash but its done nothing and after reading some of the problems that are associated with the fusion im beginning to regret buying one and long for the escort diesel estate i used to have the car before my last one. :(

#6 Malc65

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Posted 13 January 2009 - 09:57 PM

Hi im new to this site as well,and along with the sound of metal sliding about i have the same problem as you a rattle from the passenger side dashboard that's driving me mad,Ive shoved a piece of foam between the windscreen and dash but its done nothing and after reading some of the problems that are associated with the fusion im beginning to regret buying one and long for the escort diesel estate i used to have the car before my last one. :(



#7 Malc65

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Posted 13 January 2009 - 10:08 PM

Hi "Confusion", I'm sorry to say that I have still not found my dash rattle. I am sure that I shall have to remove the dash at some point because there is obviously something loose under there. Unfortunately Haynes have not yet produced a manual for this model so I am a bit stuck, plus, I must admit I am waiting for the warmer weather! By the way, one of the areas that I did find rattling was the rear folding seat backs. I taped the bars that the catches engage with insulating tape and it quietened it down. I also packed the rear doors which I suspected of rattling. If I find anything else out I will post it here for you.
Malc65

#8 confusion

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Posted 16 January 2009 - 11:15 PM

Hi "Confusion", I'm sorry to say that I have still not found my dash rattle. I am sure that I shall have to remove the dash at some point because there is obviously something loose under there. Unfortunately Haynes have not yet produced a manual for this model so I am a bit stuck, plus, I must admit I am waiting for the warmer weather! By the way, one of the areas that I did find rattling was the rear folding seat backs. I taped the bars that the catches engage with insulating tape and it quietened it down. I also packed the rear doors which I suspected of rattling. If I find anything else out I will post it here for you.
Malc65

Hi Malc65 thanks for the reply know what you mean about the cold you just don't feel like messing about with cars when you can't feel your fingers,I took mine back today still under warranty asked me if i wanted it back today and i told them to keep it as long as it takes to get it right so i can't throw any more light on the subject just yet,I know there's no haynes manual I've searched but i did come across this site don't know if its any good to you or anyone else on this site though.

http://www.gennersal...orkshop_Manuals

I don't Know if its just schematics or has written instructions like an haynes.

#9 dalminty

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Posted 18 January 2009 - 05:02 PM

Hi Malc65 thanks for the reply know what you mean about the cold you just don't feel like messing about with cars when you can't feel your fingers,I took mine back today still under warranty asked me if i wanted it back today and i told them to keep it as long as it takes to get it right so i can't throw any more light on the subject just yet,I know there's no haynes manual I've searched but i did come across this site don't know if its any good to you or anyone else on this site though.

http://www.gennersal...orkshop_Manuals

I don't Know if its just schematics or has written instructions like an haynes.



#10 confusion

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Posted 20 January 2009 - 10:06 AM

Hi "Confusion", I'm sorry to say that I have still not found my dash rattle. I am sure that I shall have to remove the dash at some point because there is obviously something loose under there. Unfortunately Haynes have not yet produced a manual for this model so I am a bit stuck, plus, I must admit I am waiting for the warmer weather! By the way, one of the areas that I did find rattling was the rear folding seat backs. I taped the bars that the catches engage with insulating tape and it quietened it down. I also packed the rear doors which I suspected of rattling. If I find anything else out I will post it here for you.
Malc65

Hi Malc65 finally got the car back after 3 days but haven't had chance to test it on the roads that usually creates the rattle.Although bringing it back it did sound a little quieter but i can still hear a slight noise.When i opened the hatch there where trace of what looked like silicon seal so it looks like they've tried to bodge it.But like you will wait until it gets a bit warmer to have a look.I've come to the conclusion that this is a design fault along with other recurring faults that a lot of people posting on this site are reporting and that is going to be virtually impossible to totally eradicate,Probably explains why they've been PX in the first place anyway good luck and hope you can find a solution. :huh:

#11 confusion

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Posted 20 January 2009 - 03:17 PM

Hi Malc65 finally got the car back after 3 days but haven't had chance to test it on the roads that usually creates the rattle.Although bringing it back it did sound a little quieter but i can still hear a slight noise.When i opened the hatch there where trace of what looked like silicon seal so it looks like they've tried to bodge it.But like you will wait until it gets a bit warmer to have a look.I've come to the conclusion that this is a design fault along with other recurring faults that a lot of people posting on this site are reporting and that is going to be virtually impossible to totally eradicate,Probably explains why they've been PX in the first place anyway good luck and hope you can find a solution. :huh:

Foot note to this post,Just been on one of my usual routes rattle no better looks like shoved a peice of cardboard in not very happy[CAR CRAFT] :angry:

#12 hendrix

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Posted 21 January 2009 - 02:17 PM

Just a bit of reason here gents .my fusion is quiet as a mouse with no undue rattles. if you take a good look around this site every model has its floors so you would be disapionted with everything. ex focus- leaking boot seals. another make maybe the much press renowed honda jazz - sticky EGR valves ,leaky tailgates. Nissan qaushqi- rear supension struts. Toyota avensis-10,000 mles clutch snaps. All cars have faults maybe youd better get push bikes or walk.

#13 confusion

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Posted 24 January 2009 - 06:26 PM

Just a bit of reason here gents .my fusion is quiet as a mouse with no undue rattles. if you take a good look around this site every model has its floors so you would be disapionted with everything. ex focus- leaking boot seals. another make maybe the much press renowed honda jazz - sticky EGR valves ,leaky tailgates. Nissan qaushqi- rear supension struts. Toyota avensis-10,000 mles clutch snaps. All cars have faults maybe youd better get push bikes or walk.

The noise is a constant irritating distraction that draws your attention to it instead of your driving.When you can't hear that there's the knock from the back to contend with,Add the poor MPG the dip and loss of power when hot,At knocking on for 60 years old i have to say it's the worst car I've had the misfortune to own.I paid far more for it than i ever have in the hope it would see me through to retirement age,if i hadn't used all my spare cash on it it would PX on a garage forecourt NOW.

#14 hendrix

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Posted 24 January 2009 - 09:31 PM

May be rose tinted glasse have been applied here the worst car ever. my father owns many cars from the past 40yrs which due to your age im guessing you may have driven( this is no insult to your age in fact i respect you because of it) i have on ocasion used these vehciles and there is no way the fusion is worse . maybe you need to think back and be more honest. on the cost front as inflation pushes prices up this is gonna be the most expensive car i bet you pay more for shopping now and petrol and clothes. Try to have some reason maybe your paticular car has problems but to slag the fusion as a whole is wrong. Mine has not put a foot wrong and alot of others on diffrent sites also have experinced no problems.posted with respect.

#15 Big Bob

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Posted 24 February 2009 - 11:12 AM

ford have a tsb on this subject concerning the lack of padding around the ventilation pipes where they come through the bulkhead from the engine so try and check if you can and add some foam padding.


I've just posted asking about a draught in my Fusion, do you think this might be the cause?

On the question of a Haynes manual, I've bought the Fiesta one which says it covers most aspects of the Fusion, although there are no specific Fusion details I assume most parts are similar :blink:

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