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Author Topic: Knocking noise from front offside  (Read 10862 times)

Offline Daza101

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Knocking noise from front offside
« on: August 28, 2016, 10:33:53 PM »
Hi,

I've got a 2013 Galaxy Titanium X with Powershift gearbox which has done around 33k miles and for the last couple of months I've had a knocking noise which sounds like it's coming from the front offside suspension when going over the slightest bump. The noise comes and goes but usually starts after going over a bumpy road, pot hole or speed bumps at slow speed. Once it starts its usually there for the rest of the day but can't be heard above 40mph.

The car's been into Ford at least 4 times but despite them replacing the front offside suspension leg, shock absorber, top mount and both anti-roll bar drop links they haven't been able to identify the cause or resolve it.
They've also tired to locate the source of the noise using an electronic listening device but that hasn't helped.
I'm told there is no play in any of the suspension or steering components and the cars recently passed an MOT without anything found.

The noise is driving me nuts but I'm now being told by the local dealer that they've run out of ideas and I'll either have to live with it until it gets worse or it might be there for the life of the vehicle!

Has anyone had a similar problem or got any suggestions what it could be?

Thanks





Offline johnnyroper

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Re: Knocking noise from front offside
« Reply #1 on: August 28, 2016, 11:08:14 PM »
Have they tried the basics like wishbone and anti roll bar bushes and ball joints? Does not sound like much else can be at fault to me with what's already been changed.

Other possible is slightly play in the inner track rod joint?

Offline Daza101

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Re: Knocking noise from front offside
« Reply #2 on: August 28, 2016, 11:25:51 PM »
Have they tried the basics like wishbone and anti roll bar bushes and ball joints? Does not sound like much else can be at fault to me with what's already been changed.

Other possible is slightly play in the inner track rod joint?

The last time it was in they checked the anti roll bar bushes when swapping the drop links.
The spring was inspected when the suspension leg and shock were replaced.
I've been told that the ball joints and other steering components seem fine and where applicable everything else has been re-torqued.

It's difficult to tell where the knocking is coming from but sometimes it sounds like its higher up. That's why I'm surprised the replacement shock and top mount didn't fix it.

The garage do seem to have been fairly thorough and even looked at the air conditioning pipes to see if they could be knocking on something.




Offline johnnyroper

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Re: Knocking noise from front offside
« Reply #3 on: August 29, 2016, 08:07:36 AM »
Sounds a bit mad for a knock over bumps etc but I had a 206 years ago that had what sounded like a suspension knock but could never find any problems. Turned out to be the top engine mount there was too much play between mounting and the bump stops.

If car is still under warranty I would not accept the response from the dealer. They have acknowledged there is a problem but have failed to find and repair it. You need to get back down there and insist they get to the bottom of it,needs to be taken higher by getting ford uk involved to look in to it further

Offline Daza101

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Re: Knocking noise from front offside
« Reply #4 on: August 29, 2016, 10:45:34 AM »
Sounds a bit mad for a knock over bumps etc but I had a 206 years ago that had what sounded like a suspension knock but could never find any problems. Turned out to be the top engine mount there was too much play between mounting and the bump stops.

If car is still under warranty I would not accept the response from the dealer. They have acknowledged there is a problem but have failed to find and repair it. You need to get back down there and insist they get to the bottom of it,needs to be taken higher by getting ford uk involved to look in to it further

The car is covered by a Ford Protect extended warranty. Most of the work they've done so far has been covered by the warranty with the exception of the top mount. Luckily I got them to swap that when they did the shock and suspension leg so I only had to pay for the part.

Unfortunately the Ford Protect warranty has loads of exclusions meaning bushes, engine, gearbox, subframe and suspension mounts aren't covered nor are diagnostics unless a covered part is replaced.

I'll certainly take it back to Ford but can't afford to run up a big diagnostics bill or randomly replace parts just in case they fix it.

thanks for your response

Offline Daza101

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Re: Knocking noise from front offside
« Reply #5 on: September 03, 2016, 04:24:21 PM »
Does anyone know if there should be much play in the drive shafts?
If I push/pull the drivers side shaft towards and away from the gearbox there seems to be a fair bit of movement and quite a loud knocking noise which sounds similar to the knocking I'm hearing when driving.

The passenger/gearbox side driveshaft has a small amount of movement but nowhere near as much and doesn't have the same kind of knock.

Offline badders1954

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Re: Knocking noise from front offside
« Reply #6 on: September 05, 2016, 02:34:52 PM »
Not much help but if you fix it let me know as i have the same problem on my 2003 mk2 and i have changed all the bushes (anti roll bar wishbone engine etc) also new track rod ends new drop link new strut new spring new bump stop new top mount new top spring cup plate new wheel bearing new bottom ball joint
and for good measure new tyre

Never to old to Rock & Roll

Ford Galaxy 2.3 mk2 2003 --

Offline Mirez

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Re: Knocking noise from front offside
« Reply #7 on: September 05, 2016, 03:02:48 PM »
There shouldnt be any (ideally) lateral movement on a diveshaft, 1 or 2mm is just about acceptable but it shouldnt be making banging noises! The in/out forces should be taken out by the inner joint, not the shaft!
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Offline Daza101

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Re: Knocking noise from front offside
« Reply #8 on: September 11, 2016, 11:05:56 PM »
There shouldnt be any (ideally) lateral movement on a diveshaft, 1 or 2mm is just about acceptable but it shouldnt be making banging noises! The in/out forces should be taken out by the inner joint, not the shaft!

Sounds like I need to get it back into Ford to check the drive shaft then because there is a fair amount of movement in the off side one.

I'm starting to think it's not suspension or drive shaft as over the last week I'm now hearing a similar knocking noise for a split second just as the engine fires up and a similar noise when turning it off.
Someone previously mentioned they'd had a knocking noise coming from the top engine mount on another car. I don't seem to have excessive movement or knocking from the engine mount but I'll get that checked by Ford also.

Out of desperation I've even tried rigging up a listening device using a microphone with a long lead plugged into the MP3 jack port for the stereo. It works quite well as I can move the microphone around under the bonnet, suspension and wheel arch and hear what it picks up through the stereo while driving. Unfortunately I still haven't worked out the source of the noise :'(
 


Offline Daza101

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Re: Knocking noise from front offside
« Reply #9 on: December 12, 2016, 11:15:26 AM »
Hi,

It's been 5 months and 6000 miles since my 2013 Galaxy developed a knocking & rattle noise from the offside front and despite 11 visits to the main dealer I've still not got it completely resolved.
To date it's had the complete suspension leg including top mount, spring, shock and bottom arm replaced along with both anti roll bar drop links and the top engine mount. All other suspension parts including steering, ball joints and bushes have been checked.

Replacement of the suspension leg has partially resolved the noise which I would have originally described as a loud clunk accompanied by a rattle when going over bumps. The clunk is gone but I'm still left with a kind of rattle as I drive over the slightest imperfection in the road at slow speed.

Numerous pipes and mountings have been adjusted to stop them coming into contact with other parts/inner wing  but the noise is still there.

The rattle isn't present when the car is cold and usually takes 15 minutes or so before it warms up and the noise starts. Once it has started it occurs nearly all the time driving slowly over any road surface. Oddly a similar faint rattle noise can sometimes be heard for a split second as the engine fires up.

Has anyone else had a similar problem or would you have any further suggestions because it's driving me mad?

thanks

Offline mike wilson

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Re: Knocking noise from front offside
« Reply #10 on: December 12, 2016, 01:30:28 PM »
This has repeatedly been shown to be handbrake cables or fuel lines, on other vehicles using the same floor pan.

Offline Daza101

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Re: Knocking noise from front offside
« Reply #11 on: December 12, 2016, 02:32:24 PM »
This has repeatedly been shown to be handbrake cables or fuel lines, on other vehicles using the same floor pan.

Thanks for the info Mike although that sounds odd given where it sounds like the noise is coming from - front offside. It actually sounds quite high up although I know sound travels.If it weren't for all the work that's already been done I would have said it was coming from the top of the suspension leg but that's all been replaced including the top mount.
I've no idea where the fuel lines run when they get to the front but it'll be worth looking into. The garage have already bent/adjusted several brake and aircon pipes in case they were touching something they shouldn't have.

In desperation I was looking at the car today thumping various bits listening for vibration/rattles. The only thing I did find was the offside front headlight rattles when you whack near where its attached. I've taken it off and tried adding a couple of rubber washers but doesn't seem to have helped. I'd be surprised I'd be able to hear that from inside anyway.

Thanks for your suggestion

Offline Daza101

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Re: Knocking noise from front offside
« Reply #12 on: January 17, 2017, 01:41:33 PM »
This has repeatedly been shown to be handbrake cables or fuel lines, on other vehicles using the same floor pan.

Hi Mike,
Have you any further info re the comment you made about fuel lines?

I've been searching but haven't been able to find any details. The cars going in to the garage yet again this week and it would be good to have as much info as possible.

Thanks

Offline mike wilson

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Re: Knocking noise from front offside
« Reply #13 on: January 18, 2017, 09:35:06 AM »
Can't find the exact post but somewhere on here.
http://www.talkford.com/community/forum/96-ford-mondeo-mk4-2007-2013/

There's also a suggestion about an exhaust heat shield rattling.  Might not apply to Galaxys.

Offline Daza101

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Re: Knocking noise from front offside
« Reply #14 on: April 18, 2017, 06:48:43 PM »
Hi,

It's been around 9 months, 10,000 miles and after 18 visits to the Ford main dealer I still have a knocking from the front off side on my 2013 Galaxy

To date the following has been done:

Checked all suspension & steering components for movement/wear
Re-torqued all bolts including subframe
Replaced suspension leg, shock absorber & top mount for new
Replaced both ARB drop links
Swapped top engine mount from another car
Replaced complete suspension leg including shock, spring, stub axle & bottom arm from another car
Engine & gearbox mounts loosened, re-aligned and re-tightened
Front off side drive shaft replaced
ARB bushes replaced
Checked exhaust heat shield
All brake, fuel, aircon, coolant pipes and wiring harnesses checked to ensure they don't rub/knock on anything
Used audio listening device to pinpoint the location but nothing found

The vehicle has been to several other garages to check suspension etc but again nothing found.
It also passed it's MOT less than 2 weeks ago.

Has anyone any further suggestions as I'm getting seriously p1ssed off with it?

In summary....
The knocking/rattle isn't present when the car is first used from cold. It usually starts after around 10 minutes or 10 miles of driving once you've driven over some bumps.
Once it does start if gets more noticeable the more drive particularly over uneven ground. The noise is present from 1mph up to 40mph before getting drowned out by road/engine noise. We haven't been able to reproduce it while the car is stationary.
It almost sounds like it's coming from the direction of the top of the suspension leg but as above the leg, shock, spring and top mount have all been replaced.
 
Any suggestions would be much appreciated.

Offline mike wilson

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Re: Knocking noise from front offside
« Reply #15 on: April 19, 2017, 11:51:46 AM »
Is this still just the rattle or has the clunk come back?

The only thing left that I can think of is the steering rack, for clunking.  Rattle could be any of the myriad shields and covers.

Offline Daza101

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Re: Knocking noise from front offside
« Reply #16 on: April 19, 2017, 09:48:35 PM »
Is this still just the rattle or has the clunk come back?

The only thing left that I can think of is the steering rack, for clunking.  Rattle could be any of the myriad shields and covers.

When the problem first started 9 months ago it was a kind of rattle/knock which once the car had warmed up could be heard over the slightest road imperfection.
The Ford dealer replaced the strut, shock and top mount for new which made the problem much worse and I then started to get a full on clunk/bang when going over big bumps or speed bumps. This sounded almost like the suspension was bottoming out. The clunk/bang was resolved when the dealer swapped the complete strut including shock, spring and stub axle from another car. I can only assume there was something wrong with the new parts they originally fitted.

What I currently have is similar to the original problem of 9 months ago.
From cold the car has no noises but after it's warmed up there's a rattle/knock on anything but a perfectly flat surface. It's more than just an insignificant rattle and sounds as if something is loose or moving around. The more the car is driven the worse it gets and at its worst it sounds as if someone has undone/loosened the wheel nuts or the top of the strut has come loose.
It's odd because the noise can't be reproduced when the car is stationary but is present as soon as it starts moving. It does it whether accelerating, coasting, braking and doesn't change whether turning or travelling straight.

I've spent many days hunting for a cause and have had the plastic scuttle panel (not sure what it's called) off from under the windscreen to give better access to that area, the bulk head and the area at the top of the strut.
I've found several areas where coolant pipes and wiring loom knock against the inside of the inner wing and the bulk head so have secured these with cable ties but the noise is still there.
I've also driven the car without the windscreen wiper arms, scuttle panel and cover on top of the engine but the noise is still there.

Inside the car I've checked the pedal mechanisms aren't loose and have checked everything I can reach behind the dash from the pedal area and by removing the pocket where the diagnostic port is.
There is a small amount of play where the steering linkage goes through the floor/bulkhead but this has been checked twice by the Ford dealer and found to be normal. Adjusting the steering column position doesn't make any difference.

I'm not a mechanic but have pretty much checked everything I can physically get to. The Ford dealer has run out of ideas also.

I'm considering taking it to an independent garage to see if they can find something Ford have missed but I suspect they'll just be rechecking the same things and I'll just waste a load of money. 
 
I'd appreciate any suggestions.

Offline mike wilson

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Re: Knocking noise from front offside
« Reply #17 on: April 20, 2017, 02:02:02 PM »
Well, the only things you haven't replaced are the steering rack and the nearside drive and suspension components.  Everything else, especially the common culprits, seems to have been dealt with.

Offline Daza101

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Re: Knocking noise from front offside
« Reply #18 on: June 12, 2017, 03:03:06 PM »
At last, after nearly 11 months and 20 odd visits to Ford it looks like the knocking I've had from the front offside has finally been fixed.
In desperation I took it to yet another garage and they immediately identified it as the top engine mount. The technician suggested it was a known problem on the Galaxy but odd that nobody else has said that.

My engine mount was previously replaced around 8 months ago from another vehicle but it looks like that unit was also duff but a brand new part has fixed it.

Offline johnnyroper

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Re: Knocking noise from front offside
« Reply #19 on: June 12, 2017, 05:25:05 PM »
Nice one hope it's all sorted for good now and you can just get on and drive it. Sounds like you happened to visit a decent dealer who quickly identified and resolved the issue for you,I know dealers don't have a good reputation but there are some decent ones out there.

Offline Bluetractorman

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Re: Knocking noise from front offside
« Reply #20 on: June 25, 2017, 09:45:53 AM »
Well done!  Glad to hear you finally nailed it.  I have the same knocking on the LHS, sounds just like yours although no warming up needed.  I've replaced anti roll bar drop link, the outer steering tie rod, checked there's nothing obviously loose, including the plastic mud guard inside the wheel arch.  This last one had cured someone else's similar prob.   Would do the anti roll bar bushes but suspect that requires the sub frame to be unbolted to get at them so beyond me.
Recently I've noticed that at slow speeds, when the knocking is audible, on slightly rough roads, it's worse if the engine is in too high a gear.  This I feel points the finger at engine / gearbox mounting bolts.  In my case on the LHS. 
Did you change these yourself?  Any tips on where and how?

Offline Daza101

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Re: Knocking noise from front offside
« Reply #21 on: June 25, 2017, 04:38:15 PM »
Recently I've noticed that at slow speeds, when the knocking is audible, on slightly rough roads, it's worse if the engine is in too high a gear.  This I feel points the finger at engine / gearbox mounting bolts.  In my case on the LHS. 
Did you change these yourself?  Any tips on where and how?

No sorry I can't really help with tips because my engine mount was replaced by the Ford dealer.

A few months ago though they did try adjusting the engine/gearbox by loosening off all the mounts, moving the engine/gearbox, then re-tightening the mounts. I was in the workshop when the guy did this and from what I saw there are 3 engine/gearbox mounts.
One under the battery box, one low down at rear of the engine/gearbox and the one I had replaced which is next to the coolant expansion tank.

I hope you get to the bottom of your noise because mine drove me nuts for best part of a year.


Offline Daza101

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Re: Knocking noise from front offside
« Reply #22 on: November 22, 2017, 08:43:45 AM »
Has anyone had to replace their top engine mount or know if there are known issues with them and/or maybe a redesigned part?

After nearly a year and around 20 visits to Ford my top engine mount was eventually replaced in May 2017 to fix a front end knocking noise. The replacement part completely cured the noise however 3 months/3000 miles after it was fitted the noise started again, very faintly at first, but has got progressively worse since.

The noise and symptoms are exactly the same as before so I suspect the engine mount again although can't believe the new one would fail so quickly unless there are known issues with the part.

Originally the problem was easy to reproduce. It wasn't there from cold but after a few short journeys and allowing the car to sit for 30 mins in between I could reproduce it at will.
Unfortunately this time the problem comes and goes and despite 4 further visits to Ford it hasn't occurred during test drives and therefore they are unwilling to take it any further until they can hear it.

I'd appreciate knowing if anyone else has had any issues with the top engine mount.

Thanks

Offline Bluetractorman

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Re: Knocking noise from front offside
« Reply #23 on: November 22, 2017, 09:07:38 AM »
I have replaced the top engine mount, albeit with one from a breakers yard.  No joy. 
My list of efforts so far is..
  • anti roll bar bush
    anti roll bar drop link
    steering outer tie rod
    top engine/gearbox mount, the one under the battery
It's none of the above in my view.  Thoughts turn to the suspension.

Offline Daza101

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Re: Knocking noise from front offside
« Reply #24 on: November 22, 2017, 09:20:39 PM »
I have replaced the top engine mount, albeit with one from a breakers yard.  No joy. 
My list of efforts so far is..
  • anti roll bar bush
    anti roll bar drop link
    steering outer tie rod
    top engine/gearbox mount, the one under the battery
It's none of the above in my view.  Thoughts turn to the suspension.

When my knocking originally started around 16 months ago it was initially diagnosed as a shock absorber/suspension leg. They were replaced under warranty and I paid for the associated top mount to be replaced at the same time but made no difference.

The garage couldn't get any more parts under warranty so then started swapping parts from another vehicle. This included the complete suspension leg including shock absorber, spring & stub axle and top engine mount but again didn't cure the problem.

Over the next 10 months or so the following was done...

sub frame was dropped and then reattached
All engine mounts loosened, engine/gearbox re-seated, engine mounts tightended
ARB bushes replaced both sides
Drop links replaced both sides
Numerous attempts at re-tightening bolts, checking brake pipes, air con pipes and wiring not loose or banging on anything

The garage also got a guy out from Ford head office down to take a look but he couldn't find the source of the knocking either. His only suggestion was to remove the complete dashboard, at great expense to me, in case the noise was behind it. I declined this suggestion. 

In desperation I eventually took the vehicle to another Ford dealership and the guy that worked on it seemed to suggest there were known issues with the air vent ducting and the top engine mount which could cause the knocking. The ducting was checked and found to be ok so he replaced the top engine mount for a new one. As I said above this totally cured the knocking for around 3 months/3000 miles but the knocking has gradually returned again.
Unlike before it's difficult to reproduce during a test drive so Ford won't do anything until they've heard it again themselves. I've been back 4 times since but despite the knocking being present on the way to the garage it stops whenever we're out on a test drive so I'm having to live with it for now and turn the radio up louder and louder to drown it out!

I'm not a mechanic but given the fact that the new engine mount fixed the issue completely for 3 months I can only assume there's an issue with these mounts and they aren't up to the job.

 

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