Neil Posted July 14, 2015 at 05:55 PM Report Share Posted July 14, 2015 at 05:55 PM My Energi has recently developed a scraping noise when it's moving. It sounds like a worn out brake pad, but it was inspected (or was supposed to be) during the last oil change (last week at the dealership) . Plus, it only has about 34k miles with a lifetime regen brake score of 95%, so I would be surprised if the brake pads were already worn. It is getting progressively worse, from last week where I thought to myself 'hmmm....I think I hear a weird noise' to today when I thought to myself 'WHAT THE HECK IS THAT HORRIBLE NOISE!!'. What else could make a noise like a brake pad warming tab on a rotor? Quote Link to comment Share on other sites More sharing options...
Hybridbear Posted July 14, 2015 at 09:35 PM Report Share Posted July 14, 2015 at 09:35 PM How loud is it? Is it noticeable at all speeds? Quote Link to comment Share on other sites More sharing options...
storksb Posted July 14, 2015 at 11:09 PM Report Share Posted July 14, 2015 at 11:09 PM Does it change with speed? Or is it constant? Maybe you have a sticking caliper causing the brake to rub. Quote Link to comment Share on other sites More sharing options...
jeff_h Posted July 15, 2015 at 12:30 AM Report Share Posted July 15, 2015 at 12:30 AM ...and does the sound change (or go away) if you lightly apply the brakes, especially at low speed when the friction brakes would be used? And can you tell which wheel is making the noise, or is it just coming from "somewhere" but you're not sure where? Quote Link to comment Share on other sites More sharing options...
Neil Posted July 15, 2015 at 05:32 PM Author Report Share Posted July 15, 2015 at 05:32 PM All great questions. The rhythm of the noise does increase as I speed up, but it does not change if I put on the brakes (weird!). It is not audible inside the cabin, unless I am driving next to something that reflects the sound back at me - like a Jersey wall or a row of parked cars. I ran my finger across all four rotors, and although they are not as smooth as i would expect, they are all four the same - no out of the ordinary scoring on any of them. I can't tell where the noise is coming from since I only hear it when it is reflected back at me - so it always sounds like the left front. I'm going to pull the front wheels off this weekend and have a look at the pads. What kind of mileage have other people gotten out of their OEM pads? Quote Link to comment Share on other sites More sharing options...
Russael Posted July 15, 2015 at 05:39 PM Report Share Posted July 15, 2015 at 05:39 PM (edited) I hear a metal to metal noise while backing out of my garage to the street (I pass between my house and the neighbors as my garage is in the backyard), but I know it's the brakes. I can step on them and the noise changes slightly from a light swirly noise to something that almost sounds like paper being rubbed together due to the friction. I know you said your noise doesn't change when you depress the brake, but you may be getting regen rather than using the friction pads. While rolling, pop it in neutral and then hit the brakes and see what it does. Your pads may be glazed a little since they're probably not being used that frequently. The only things that would likely make noise down by the wheels while you move are your brakes, wheel bearings, half shaft u-joints, and maybe the rubber boots that surround them. Only other thing it could be is the transmission, but I think that would generate more of a whine (if it is the electric motor going) or a rumble (if something was wrong with the gears). Edited July 15, 2015 at 05:41 PM by Russael Quote Link to comment Share on other sites More sharing options...
Timewellspent Posted July 15, 2015 at 07:26 PM Report Share Posted July 15, 2015 at 07:26 PM I have the same type of noise that I hear when the windows are down and I hear it, as you say bouncing off something. I wrote it off as being normal for a hybrid as this is my first, but now you have me wondering. I have a road trip coming up and an appt when I return for my 10K service to do my oil change and tire rotate so I will see if anything changes after this is done. Quote Link to comment Share on other sites More sharing options...
Hybridbear Posted July 15, 2015 at 07:46 PM Report Share Posted July 15, 2015 at 07:46 PM We hear a whirring noise when rolling. I can hear it best when in our underground parking garage at home. I will have to check again tonight to confirm, but I'm pretty sure our noise can be heard when in Neutral just rolling. It sounds like a brake pad rubbing. But I've never thought much of it. Now you have me curious too... Quote Link to comment Share on other sites More sharing options...
expresspotato Posted July 15, 2015 at 10:50 PM Report Share Posted July 15, 2015 at 10:50 PM (edited) Could be a stone in rotor / brake pads... Figure out what side its happening on and take it in. Edited July 17, 2015 at 12:13 AM by jeff_h Quote Link to comment Share on other sites More sharing options...
Neil Posted July 16, 2015 at 02:10 PM Author Report Share Posted July 16, 2015 at 02:10 PM ... you may be getting regen rather than using the friction pads. While rolling, pop it in neutral and then hit the brakes and see what it does. That is a really good point. I'll try that today. Quote Link to comment Share on other sites More sharing options...
isaaktnt Posted July 16, 2015 at 10:28 PM Report Share Posted July 16, 2015 at 10:28 PM (edited) I hear some light rubbing sound driving in L and coasting... put it in D and noise goes away.. assumed that its the regen process.. anyone know? Edited July 16, 2015 at 10:28 PM by isaaktnt Quote Link to comment Share on other sites More sharing options...
Neil Posted February 3, 2020 at 07:14 PM Author Report Share Posted February 3, 2020 at 07:14 PM I replaced the front brakes and rotors and inspected the axle hub assemblies. It does not appear to be a bad axle bearing. The noise is getting progressively loud and noticeable. I'm afraid I'm goign to have to take it to the dealership and have them look at it $$$$$. Quote Link to comment Share on other sites More sharing options...
Bookkeeper Posted February 16, 2020 at 12:38 PM Report Share Posted February 16, 2020 at 12:38 PM (edited) Sorry, this falls into one of those "ya me too" posts... just my screen shows the second last comment was in 2015 and the last comment Feb 3 of this year. Seems pertinent to say that my Fusion also has the same problem. Mine is a recent purchase, Nov 19, from the dealer at 135km on the odometer, 2018 model Fusion Energi. The sound is coming from the front passenger side and sounds/feels exactly like a worn brake shoe rubbing, metal on metal (same sound described by others on this thread). I have the extended warranty plan for 5 years and when it goes in for the 6 month check I will ask them to look at it. Easy to reproduce the sound, just no time to take it in now I need it to perform. Will post again after that. Cheers, Edited February 16, 2020 at 12:39 PM by Bookkeeper Quote Link to comment Share on other sites More sharing options...
Kman Posted October 10, 2020 at 01:42 AM Report Share Posted October 10, 2020 at 01:42 AM Neil / Bookkeeper...what did you ultimately find? My second Fusion hybrid but first time to have this issue. Not the normal regen sound. Its horrible; metal on metal as you describe, like worn brakes. Coming from BOTH sides on the front. Our road is under repair and pretty rough so I thought it was a rock in the brakes, but what are the odds to have that on more than one wheel? I will pull wheels tomorrow to look, but wonder what others ended up finding. This is on a 2019 Fusion Hybrid with less than 35K miles. Thanks! Quote Link to comment Share on other sites More sharing options...
Mark A Posted February 12, 2021 at 03:08 AM Report Share Posted February 12, 2021 at 03:08 AM (edited) Sorry to drop in so late on the feed but I am having the same problem. 2015 Fusion Energi Titanium. 108K miles. I kind of discribe it as a humming sound at the speed of rubbing your hands together. As I leave a stop, the rubbing gains in speed as the car does. Always the same sound at the same volume level. Not real loud but loud enough to think others outside can hear it. I can't hear it at speeds over 40 because of road noise, or the bitchen stereo. I had a service today and they checked the brakes and rotors and found nothing. Other than that, I love my car! Has anyone had any luck or diagnosis? Thanks to all. Edited February 12, 2021 at 03:13 AM by Mark A Misspelled word Quote Link to comment Share on other sites More sharing options...
g-win Posted May 28, 2021 at 12:30 PM Report Share Posted May 28, 2021 at 12:30 PM I hear this noise too on my 2019 Ford Fusion Energi Titanium with 20K miles. Like others said, I hear the sound bouncing off other cars/walls when accelerating. I can't determine where it's coming from, but I hear it very well from the driver's side window. Quote Link to comment Share on other sites More sharing options...
Neil Posted June 29, 2021 at 01:26 AM Author Report Share Posted June 29, 2021 at 01:26 AM I took it to the dealer and he was able to locate the noise. It's a bearing on the regenerative braking mechanism. Unfortunately the regen unit is located inside the transmission bell housing, and it can not be serviced. The only solution is a new transmission at about $9,600. I'm going to live with it and drive the car until it causes a catastrophic failure. Then take the license plates off of it and RUN! I changed the transmission fluid a bit early (125k miles) to see if that would help. It was surprisingly easy to do, and only cost a little more than an oil change (~$60 in parts and an hour of time). I was encouraged that there was no metal filings on the magnetic drain plug, and the fluid didn't look that bad. The fluid change definitely quieted down the scraping noise - maybe the fresh fluid will slow the wear on the bearing some as well. Regardless, it's pretty much a 'dead car walking' situation. I don't have much hope for this car, but I'm at 127k miles now, so if I get another year out of it it won't be as bad as it could have been. I always drive my cars for 10 years and 150k miles, but this one simply is not going to make it. Quote Link to comment Share on other sites More sharing options...
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