Hi all.

I expect this topic has been done many, many times, but I wonder if someone would give me some advice.....

I have had a knocking noise from the front of my Focus 1.8 zetec for around two years now, becoming noisier and noisier. I have had four separate mechanics investigate it, but none have succeeded in correctly identifying the cause, and it's really getting annoying now!

Here's what's been done.......

Garage #1:

Thorough unspection and test drive, but unable to find any faults. Recommended waiting until MOT to see if it flagged anything up.

Garage #2:

This second garage carried out the MOT, but no relevant fault was highlighted. I asked the mechanic if he'd investigate the knocking noise. He did - crow bar was in full use on all the usual suspects of steering and suspension.

In the end he held his hands up and couldn't identify the culprit. He suggested replacing the most common cause on a Focus - the control arm links (or could have been the anti-roll bar links ?).

He replaced these, but no fix. Cost £50.

Garage #3:

Unable to identify the fault. Was extremely determined to fix it, as didn't want to be beaten. After having vehicle for a whole day, he said the only thing he could see that was showing signs of wear was the steering rack. He replaced it for me. Cost £330.

No fix!!

Garage #4:

Car went in for a Cambelt and Cat change. I asked if they would look at the knocking noise. Once again, no idea what was causing it.


Now, this noise is pretty bad. It's not just me being picky. It's now embarrassing to take people in the car, lest they think it's dangerous!

Here's a bit of detail about the noise....

• When I go over large bumps (such as speed bumps) it often doesn't make the noise, but it's more on smaller bumps.
• It's sometimes a single knock, but usually a series of knocks.
• It seems to be on the driver's side more than anything
• It isn't brought on by turning corners
• It rarely does it at speed
• I can produce the noise at will, by putting the car into the wrong gear. (I know that will always make the car rumble, but this is a knocking noise).
• I have no gear change problems
• No jerking from the engine or gearbox
• Car drives fantastic apart from this noise.

I have read somewhere that it could be the rear engine mount? I inspected this just now, and to my untrained eye it seemed to be okay. It certainly wasn't loose, but I was able to move it 3 - 4 mm with a crowbar.

Sorry for the rambling first post, I just want to get this sorted out.

Any help will be very welcome and greatly appreciated.

Thanks in advance.

 

if it wax the back gearbox mount i would check it by pulling the hand brake on hard, putting the caf into gear and work the clutch pedal to put load on the engine causing it to rock. The noise could be shockers but i would of thought it would knock must of the time.

 

the rear gear box mounts are very common for wearing out, you have to take them off though to check their condition. i'd be checking that next!

 

Thanks for your replies, lads.

When you say rear gearbox mount, do you mean this?...........


http://media.photobucket.com/image/e...a0/photo02.jpg

This is what I checked this morning, and it looks an easy job to do. So if that fixes it, I'll be very happy indeed.

 

That's the one, they do wear out quite quick on the focus's.

 

Thanks for the suggestion Glenn.

I've just tried this but with no noises or other unusual effects. Would you say that this confirms that it is NOT the gearbox mounting at fault, then?

I just found a new gearbox mount on eBay for £27. I guess, at that price it's maybe worth doing anyway?

 

Also, when you change it, be sure to put the bolts back in the correct places, the two bolts that hp through the mount are slightly different lengths, the shorter one goes vertically through the mount and the longer one horizontally, if you mix them up, the vertical bolt will foul the steering rack, causing a cracking sound, and can also damage the rack.

Karl

 

take it to a BETTER garage? lol

 

Worth checking top strut mountings

 

put some lube of some sort on the two top coils of the front springs cause the top of the coil spring go weak and start rubing on each other over bumps.

 

In my car (focus) it turned out to be the drop links on the front suspension which were worn and allowing movement in the anti-roll bar. One end of the link is attached to the strut and the other to the end of the anti roll bar (one each side!). I replaced them myself and it solved the problem. Like you, I had mechanics check the mountings, front and rear, to no avail. The drop links are a common problem on the Focus - so I was told by the motor parts shop which keep a good stock of them. To replace them you need a few different spanners and you need two of the same size - one to hold the nut to the rear while you loosen the nut to the front. Annoying job but easy enough to do with patience!

 

In the case of knocking noise from my car, it was only audible when driving under 30mph and it was hard to determine whether the noise was from the front or rear of the car.