general problems of the 2011 Ford Fusion - part 2

While performing the first tire/wheel rotaion on our new 2011 Ford Fusion sport with aluminum wheels more than one wheel stud broke off when torquing to factory specifications. The factory manual calls for a torque of 100fp. Initialy lacking the factory torque spec I started with 75fp and even at 75fp felt one lug nut turn what felt like too far as compared to the others. I obtained the torque value from the owners manual (100fp) and proceeded to complete the torque to the recommended 100fp. One stud then twisted off prior to reaching 100fp. Having seen that the NHTSA is performing an investigation I thought I would add the following. It occures to me that with the aluminum rims and the shape of the lug nut there may not be enough friction between the lug nut and the wheel to allow for proper torque.

Had to have flat tire repaired. When technicians tried to place wheel on 2011 Fusion two (2) of the wheel bolts twisted and would not hold at the required torque level. Had to replace two of the five wheel bolts. Took car to Ford dealer to have all wheel bolts replaced. Their response was that they could not find anything wrong with bolts, had no technical bulletins, safety issues, recalls, etc. And would not even repay for the two bots that were deformed. The two deformed bolts were given to the Ford service department. I gave them evidence of the problem, complete description, repair shop that found the problem, ( whom I have used for over 30 years), and got the answer, if it happens again bring it back. I hope when I bring it back it is not after an accident where someone is injured. If you have questions, please contact my father, kenneth seal.

Recall 11s23 I sought service on 2/9. A month later the Ford dealership still does not have the parts to fix the problem.