Rattles behind dashboard on Ford Fusion 2 '05 plate.
I have terrible rattles, especially on rough roads (everywhere round here!). They are coming from behind the dashboard, seems to be under where the windscreen heater vents are situated. I have removed the instrument cluster a couple of times but the dashboard seems to be a moulded unit with no access. Have looked under the steering wheel and removed the glove box searching for obvious loose items but all seems tight. I think I shall have to remove the dashboard but cannot find a Haynes manual. Can you help?
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This can be a sound made by "cam phaser" engines that Ford made for 4 or 5 years. Usually the noise quits above 2000 rpm as the phasers limit out in their travel. These engines are very sensitive to the correct weight oil being used and a Ford filter being installed.
The noise has been described as a muffled diesel rattle. Owners report stalling, hesitation, poor acceleration, but most do experience vibrations. What is happening is each bank of cylinders is suppose to be synchronized by the phasers. Imagine if half of the valves are firing several degrees earlier or later than the other half of the engine. Since these adjustments constantly change it makes trouble shooting difficult.
Other areas for rattles are the beads in the catalytic converters which may loosen and float inside the converter or even loose baffles in honeycomb design converters.
I have had terrible noises coming from gravel and rocks trapped in between the heat shields of catalytic converters especially if you travel gravel roads. Since you have "knock sensors" you can get driveability problems from the engine trying to misinterpete the knocks and rattles caused by rocks.
broken spring top. damaged damper. steering idler. bearing plate lose. steering link damaged. would need to jack up that side at test every thing in list. could also be something lose in the side part behind the plastic covers. like a droped spaner
finding noises is hard work and is ART. get help. 1;: is it the dash it self, press on it, doe that stop of change pitch of sound. no? 2: i must be something inside. use a cheap rubber hose to your ear. and move hose all over dash underneath to find the true source. you never said under what conditions, it rattles. parked (rats/mice....), idling,, moving, or only bumps in road. or only during earth quakes, (LOL)