DoubleDown Posted September 15 Share Posted September 15 (edited) Hey All, I took my fusion in for preventative maintenance to get it ready to turn over to my 16 year old son to drive. The car had no issuesreally except for the PTU was overheating and disengaging during highway speeds so I paid a local shop to replace it with a brand new Ford part. After they did all the work after turning out of their parking lot I heard a "clunk" (it almost sounds like if you tap your hand on a wooden desk with a medium amount of pressure). I didn't think much of it but noticed every time I made a turn it was doing it (both directions). I brought the car back to the shop and they of course claimed it was nothing they did, but came back saying the driveshaft had serious signs of wear and needed to be replaced or resurfaced. I went with the rebuild option from a local driveshaft shop and that did not fix the issue. I brought the car back to them a third time and was told it sounded like something in the differential. Frustrated at this point (and the fact they wanted to charge me $5k for a new diff) I bought a used differential off ebay from a 20k wrecked vehicle and had another shop put it in. I got the car back, reprogrammed the RDU to the computer as recommended, and the clunking sound remained. Brought the car back to the second shop and they had it a month and called a Ford specialist that could not determine what it was outside of the viscous coupling appeared to be leaking oil and was bad. I went ahead and had them replace it and the clunking sound remains. At this point I don't have any more money to invest in the car and despite what everyone is telling me, I truly believe the issue has to be in the suspension somewhere that the first shop messed up. Here is what was done on the car from a maintenance perspective: -Brake pads replaced -Rotors replaced -PTU replaced with new ford part -Engine and acessory belts replaced (was making noise before this) -Original differential had fluid drained and refilled -Differential replaced (used 20k differential, was in good shape) -Viscous Couplin replaced -Transmission fluid drained and replaced The clunking sound typically happens once around the 2-3 shift and it only will occur if you are turning the steering wheel and start to straighten the car back out after a turn. If you go in a straight line the car will not making the clunking sound no matter what speed you give it. Highly frustrated at this point, not sure where else to go with troubleshooting and don't want to give up the car. Was thinking the sway bar bushing but just verified they are nice and solid. Ty for the help. Edited September 15 by DoubleDown Quote Link to comment Share on other sites More sharing options...
twintornados Posted September 15 Share Posted September 15 Engine cradle mounts Quote Link to comment Share on other sites More sharing options...
DoubleDown Posted September 15 Author Share Posted September 15 (edited) 2 hours ago, twintornados said: Engine cradle mounts Thanks. Is there a way to test them while still in the car? There are 0 vibrations so I wasn't assuming it would be related to the mounts. Also forgot to mention the sound is coming from the rear of the car. Edited September 15 by DoubleDown Quote Link to comment Share on other sites More sharing options...
twintornados Posted September 16 Share Posted September 16 11 hours ago, DoubleDown said: Thanks. Is there a way to test them while still in the car? There are 0 vibrations so I wasn't assuming it would be related to the mounts. Also forgot to mention the sound is coming from the rear of the car. Sounds travel....have your mechanic check them by moving them with a pry bar Quote Link to comment Share on other sites More sharing options...
DoubleDown Posted September 16 Author Share Posted September 16 6 hours ago, twintornados said: Sounds travel....have your mechanic check them by moving them with a pry bar I did a quick test with my son and I'd say you are right based on what I am seeing. Does this much movement look normal to you for such a low rev? I did it in both reverse (first part of video) and then drive (second half). https://photos.app.goo.gl/Ma61BZ8GRe5GxmxX7 Quote Link to comment Share on other sites More sharing options...
twintornados Posted September 16 Share Posted September 16 5 hours ago, DoubleDown said: I did a quick test with my son and I'd say you are right based on what I am seeing. Does this much movement look normal to you for such a low rev? I did it in both reverse (first part of video) and then drive (second half). https://photos.app.goo.gl/Ma61BZ8GRe5GxmxX7 That does seem excessive - check motor and trans mounts Quote Link to comment Share on other sites More sharing options...
DoubleDown Posted September 16 Author Share Posted September 16 Does anyone know the part # for the trans mount? I assume the engine mount uses the same part for all 3 - Ford DG9Z-6038-J Quote Link to comment Share on other sites More sharing options...
Multitask Posted September 17 Share Posted September 17 Sounds like you plan to DIY. If you feel confidant about doing that , and there is nothing else that might fail that goes along with what you 'think' it might be, I'd say go for it.... Being it's about 10 year old, just so that IF they find it's something else, or needs something else.... then you would be covered for that (as long as they cover their work). 😎 https://www.car-part.com/ That is a good place to start. 😎 Quote Link to comment Share on other sites More sharing options...
DoubleDown Posted September 17 Author Share Posted September 17 18 minutes ago, Multitask said: Sounds like you plan to DIY. If you feel confidant about doing that , and there is nothing else that might fail that goes along with what you 'think' it might be, I'd say go for it.... Being it's about 10 year old, just so that IF they find it's something else, or needs something else.... then you would be covered for that (as long as they cover their work). 😎 https://www.car-part.com/ That is a good place to start. 😎 18 minutes ago, Multitask said: I would have a local shop do the work. I am still going to run some more tests before I pull the trigger as I am not 100% convinced it is the mounts just yet, but I a still have no better leads at this point. Looking at picking up a mini cam I can mount under the car to help narrow down where it is coming from. Quote Link to comment Share on other sites More sharing options...
twintornados Posted September 27 Share Posted September 27 @DoubleDown what is the result? Quote Link to comment Share on other sites More sharing options...
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