Rough ride, suspension thud

[Jerry]

Hello everyone, first post here!

I’m trying to diagnose a problem with my 2011 Ford Fusion’s (SE V6 3.0L) front suspension and I’m wondering if you guys might have any ideas. My car has been driving pretty rough for some time, especially the front. Bumps feel like hitting a curb, small potholes feel like the car just fell of the cliff. There’s usually a thud, as if there was nothing to cushion the car

A year ago I have replaced upper (Dorman) and lower rearward (Moog) control arms, driver side, as well as struts (Gabriel). Of the whole strut assembly, only the strut was replaced, and the spring, mount, etc. were reused. A couple of months ago I had front sub-frame bushings replaced. I took the car to a couple of shops around and they all suggested that the struts were at fault, as they were “not opening fully”.

Last week I decided to replace the whole strut assembly on both sides, so I got the Monroe quick struts and shocks. So far I have installed the front struts only and with the new struts in place, the ride has improved some, especially over very small bumps and uneven patches of road, but anything bigger than that and the roughness is still there.

I welcome your suggestions!

Topic

[college man]

check sway bar end links. struts do dampen the suspension travel. Could be struts.

[Jerry]

Thanks for your feedback.

I have replaced both stab links a few months ago, which improved handling significantly. I have just replaced the front struts last weekend, per my original post.

Any other ideas?

[Mark Babunovic]

Have you replaced the sway bar bushings?

[Bill]

How much air pressure is in the tires?

[Jerry]

Tire pressure is at 35PSI in all four tires, which is what the sticker on the door jamb says.
I have not checked sway bar bushings, should I inspect them for cracks and play?
I was also thinking the engine mounts maybe? but would these cause such roughness?

[Larry Bible]

Noise and vibration are among the most difficult problems to troubleshoot from afar.

This is not a situation to approach by throwing parts at it. The four P’s are your best method for finding your problem, if there is one. If the problem is not just an irritatingly stiff riding car, the car needs to go in the air and the four P’s applied; Push, Pull, Pry and Prod everything underneath. Check all suspension joints and bushings, shake the exhaust system and so forth. Make sure there are no suspension joints or bushings that are binding.

Without being able to touch the car with my own hands, this is about the most help I can offer. Hope it helps in some way.

[Mark Babunovic]

http://www.ericthecarguy.com/suspention-and-steering/516-finding-and-repairing-rear-end-noise-honda-element-crv

Worn sway bar bushings can make a big difference front and back.

[Jerry]

I have visually inspected the sway bar bushings last weekend and they looked intact. No tears, holes, anything like that. Can they still, possibly, be the issue?

[Mark Babunovic]

If you don’t have any up-down play (try grabbing the swaybar with both hands and jiggling it, or smacking it with a rubber mallet) then you’re fine. As the bushings wear the holes gets bigger, allowing the swaybar to bounce against the frame and amplify every bump or rut.

If you do need to replace them I would go OE — it sounds trivial, but the Advanced Auto replacements for my Accord were spongier, and one hole was noticeably larger than the other in the same pair (which are different front vs. back). Back they went.

[Jerry]

Thank you, I’ll try that. As far as I can tell, the sway bar is only exposed by the stabilizer links, so I guess one option is to get under the car, grab the sway bar like a barbell and start wiggling B)

[Author]

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