Good afternoon all.

I'm banging my head against the wall with this one and hope someone can help me.

About a month or so ago I replaced the clutch, flywheel and slave cylinder in my 2003 mondeo mk3 130 tdci. Whilst the sub-frame was off I thought I would take the opportunity to overhaul the front end so I bought replacement springs (one had actual cracked so they needed replacing), new track rod ends (the old ones had seen better days), and wishbones (the ball joint gaiter had split on one). Everything was replaced in pairs.

I changed the clutch and bolted everything back together, using the ford alignment pins to align the sub-frame (which lined back up to its original markings).

Now I have a knock coming from the o/s/f. It mainly does it if I am turning full lock, but it isn't clicking like a cv joint, more of a suspension knock, it also rarely (but sometimes) makes the noise when traveling straight ahead. When it knocks I can actually feel it on the floor and in the steering, and I had a passenger in the car the other day and she said she could also feel it on the passenger foot well.

I have had both wheels off and checked that everything is tight, which it is, and also check the rack and cv joints and they all seem fine.

I'm really lost but need this fixed asap, I'm driving on holiday (500 mile journey) in it very soon so it has to be perfect for then.

Please, does anyone have any ideas?

p.s. the rack used to suffer from the notchy center issue which appears to be a common fault with these cars, however it does seem worse since this noise has developed. Also the steering does seem to feel very wooly (if i am turning full lock and hit a patch of water or anything it feels like the car is sliding all over the shop). The car now handles like crap in the corners to which must be something to do with it?

Thanks again, Phil.