DIY, trunk lid Strut and Fuel Door Cover

[d5rocket]

Hi, I am a new Fusion Energi owner for about a month and a half now.  It's a nice PHEV, but there are a few minor flaws like the droopy trunk lid and a fuel door button that is so easily activated unintentionally.  So here are my simple fixes.  They are not the most elegant and optimal solutions, but they are mine and simple. 

 

For the droopy trunk lid, all you need is a strut made from a bent rod, a piece of wood or an aluminum angle in my case.  I have enclosed a few photos.  It's fairly non- destructive, simple, and removable without tool.  You drill a hole in the trunk lid arm for receiving the pin; cut a 12 inch bar and a notch at the bottom to rest the bar on the bolt that is already there (sticking out, with a cap).  Bend the bottom notch to better conform to the contour.

 

The guard or cover is a simple L piece to span over the fuel door switch.  Wedge it into the gap.  The bend should be high enough so there is no contact of the cover to the switch surface.  The underside of the cover is lined so it will not scratch the plastic trim in case of contact.  It is removable so you can push the fuel door button only when intended.  I don't want to provide the boring details as it is very obvious and intuitive to the most casual observers.  My 2 cents worth if it helps.

Edited December 17, 2013 at 07:19 AM by d5rocket

[apm]

Hi d5rocket,

 

There is a TSB for the saggy trunk... Check the Maintenance Discussion on this forum for the TSB number.

 

Some dealers are obtuse and they may tell you that the lid is working the way it should, and they will try to compare your car with another car with a spoiler, when it is the spoler that causes the trunk to sag. This happened to me at one dealer, I had to get Ford Customer Service involved and go to a different dealer to have the work done. It works much better now, no need for a strut!

 

Regards,

APM

[d5rocket]

Thanks apm for the lead.  I've found it in the Forum's maintenance section, TSB 13-5-18 (Luggage Compartment Lid Will Not Stay Open).  It covers certain models with a spoiler and built before May 2, 2013.  Mine was built in April and does not have a spoiler on the cheap SE model.  My trunk lid with no spoiler still sags when the car is parked on a slight uphill grade.  It calls for removal and replacement (with new, stiffer?) torsion spring rods.  I will call my dealer to see if I can get it fixed for free.  But I will still keep my DIY strut as a spare for really severe wind condition, or as motivation tool on ornery dealer.

Edited December 20, 2013 at 04:54 PM by d5rocket