Transfer Case Problems of Ford Fusion

Tl the contact owns a 2011 Ford Fusion. While driving 60 mph, the contact heard an abnormal noise coming from the vehicle. Prior to the noise, the contact noticed a burning odor. The vehicle was taken to an independent mechanic who found grease inside the transfer case. The vehicle was taken to paramount Ford of valdese (101 malcolm blvd suite a, valdese, nc 28690, (828) 338-9348) where it was diagnosed that the transfer case needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 60,000.

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Vehicle is a daily drive, experienced TSB 13-4-17, pcm failure causing the ignition coils to burn out on cylinder 4. Vehicle was towed to Ford dealership, where vehicle was repaired, at a cost of over $2000. Immediately after the vehicle had a howl and vibration, vehicle was taken to a local mechanic and diagnosed as a transfer case (ptu) failure, this was a few days after leaving the Ford dealership. My local mechanic replaced the ptu at a cost of $1000. Vehicle was fine from November 2013 till just this past week March 6 2014 where a leak of gear oil was found in the driveway, car was brought to local Ford dealership which confirmed a leak of the seal on the transfer case (ptu). Vehicle has been brought to local mechanic that made the repair. I find it unbelievable that since this vehicle has hit 100k miles that it is in need of constant repair. I have owned many Fords and have never had an issue like this. After much research I have found that these are common problems!! Ford needs to do something about this!! they claim to have reliable vehicles but this is not reliable, especially since I bought this car as a certified pre-owned from a Ford dealership in July of 2010 I only got 3 good years out of this vehicle. Its a shame cause its such a beautiful car and now I have nothing but mechanical issues.

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Ptu (transfer case) is leaking out of vent tube. Because the ptu oil is not serviceable (no drain plug) the oil has degraded and turned into a thick tar like substance clogging up the unit. Now unit makes whining noise during acceleration destroying the gears.

See all problems of the 2008 Ford Fusion 🔎.