Ok guys, try this one! I have a 2005 ford galaxy 1.9TDI with a strange suspension knock. Last year I had a strut top mount replaced for the MOT and, ever since then, I have had a strange knocking going over bumps. The noise comes from the front left ( the corner that the mount was changed.). The mechanics at my local garage have tried several times to find the problem without success. I am a retired mechanic myself and am mystified. The following things have been checked or changed in the process:  lower arm, ball joint and bushes, track rod end, drop links, anti- roll bar bushes, wheel bearings, engine lower tray, There is no oil leakage from the shock absorber which seems to work well. The spring is intact and the strut appears to be in good shape and properly mounted.

In desperation, we have also checked the exhaust, left rear suspension and just about everything attached to the underside of the car.

The noise, as far as I can describe it, is a slightly muffled knock, definitely not metal-to-metal but reminiscent of a worn anti-roll bar bush (but it's not that)

The only thing not changed or checked beyond physical examination is the strut itself I am reluctant to just swap it out on the off-chance that it might be that, because I have already spent considerable sums on this problem and am reluctant to change the strut unless I am sure that that is the problem.

Any suggestions will be welcome. Thanks in advance

 

The spring might not have been compressed fully when the Strut was rebuilt. I had this problem once myself and now tension the spring again after rebuilding and check the gland nut can't be tightened anymore. 

Although the noises would be different and I could be wrong but probably worth it for you to find out more, but I believe the VW built Galaxy, Sharan and Alhambra suffered from driveshaft problems...seem to  remember a work colleague of mine having them changed on his Sharan.