It is definitely unusual for the shafts to make such a noise - I have a theory that the previous owner ran the suspension into the ground so much that he has virtually ruined every component - but I could be wrong - just seemed odd that front and back shocks needed doing and then lots of other bits - tie rods etc 

as you can see the joint on the shaft seems to have inhaled water and the bearing fell apart as soon it was free 

 

Unbelievably after new driveshafts and new lower arms with new ball joints it is still making this retched noise ! 

Now we have virtually rebuilt the mondeos suspension, the head scratching continues as to what it could be, bits of bodywork & trim have been ruled out by removing them ( bonnet, plastic trays top and bottom, scuttle tray etc ) and still getting the noise when moving. With the cars front wheels up on independents ramps ( I don’t have a lift ) when the steering is moved left to right slightly ( as much as a ramp will allow) there is a knocking from the rack on the drivers side which causes a noise to the track rod. However it’s difficult to see how such a relatively low volume noise could be so noisy when the car is in motion. 

Mondeo madness continues 🤯 with the bonnet removed the noise doesn’t become any clearer. Listened to the shocks with an automotive stethoscope when the car was in motion and heard nothing. Continued to look around the cabin and found the drivers seat a bit loose , so took it out and tightened it but no joy. Checked the exhaust again as there was some noise from the mounts but it wasn’t the noise. The search for the illusive knock continues into all kinds of crazy realms. 

Having done a bit of research over possible noises I’ve found 3 possibilities :

1) steering rack- it seems most of the early mk4’s had racks recalled under warranty. Although most whine or squeal, it seems some do knock. We’ve found a knock when the ignition is off but can’t replicate when the engine is running- however as we get the noise engine on or off, I need to do a bit more digging to try and ascertain if it’s actually the rack.

2) pinch bolts on the lower ball joints - we’ve replaced the lower wishbones/arms and the ball joints were included so all the pinch bolts are new.

3) handbrake cable - I’ve read that one owner had trouble with knocking and it transpired it was the handbrake cable knocking on the swing arm. I’ve not checked this out yet.

Handbrake cables all good , so inspected the the rack some more and eventually had a break through- whilst taking the passenger side apart again to look at the shocks again we found that the inner & outer tie rod clonked when it dropped- as both rods are new it could only be the rack. You can hear the knock coming from the rack where the inner tie rod joins. New rack going in tomorrow- if it’s still banging after that I’m gonna burn it to the ground ! 🔥

1 hour ago, Mon-day-ut-oh said:

after that I’m gonna burn it to the ground ! 

well don't use petrol, have you seen the price of it ? 🤣

Where are my matches……🔥

***** b@$t@rd thing is still banging despite a new rack- the only thing left that I can think of is the shocks, despite being new, are poor quality.  I’ve also read that non-OEM drop links can cause issue but given they’ve been replaced and it was doing the same noise before and after it seems unlikely 

Im off to find a dark corner to cry in 😭

You can remove the drop links and drive a short distance without them to rule those out for free.  Just don't take any corners too sharply!

1 hour ago, Mon-day-ut-oh said:

Where are my matches……🔥

***** b@$t@rd thing is still banging despite a new rack- the only thing left that I can think of is the shocks, despite being new, are poor quality.  I’ve also read that non-OEM drop links can cause issue but given they’ve been replaced and it was doing the same noise before and after it seems unlikely 

Im off to find a dark corner to cry in 😭

This car must be costing you a fortune  ☹️ 

1 hour ago, dezwez said:

This car must be costing you a fortune  ☹️ 

Oh yes ! So far it’s had new : 

Rack
Driveshafts
Lower wishbones/arms
Lower ball joints 
Inner tie rods
Outer tie rods
Arb bushes
Drop links 
Shocks

Subframe bushes are another consideration too out of the few remaining 

well Tizer was right, turns out the new shocks were cr@p - replaced them and the noise is gone. Although it was an expensive experience, I think the only part that didn’t need changing was the drop links so at least it is now steering and rolling much better and shouldn’t need any front suspension for a while ! 

21 minutes ago, Mon-day-ut-oh said:

well Tizer was right, turns out the new shocks were cr@p - replaced them and the noise is gone. Although it was an expensive experience, I think the only part that didn’t need changing was the drop links so at least it is now steering and rolling much better and shouldn’t need any front suspension for a while ! 

That's good news and your car will drive drive a lot better.

I normally keep my cars for a long time and change my Shocks after about 6 or 7 years just for the comfort factor knowing that I will get several more pleasant  years of driving for my investment instead of several bad years until they have to be changed.

Yes I would agree a good approach- I think the previous owner opted for the ‘ drive it into the ground ‘ approach 🙄

That was a shocking waste of time! (see what I did there...?)

Can you recall the make of the shocks you'd fitted that proved to be a total disaster.... and which make have you fitted now? 

On 7/16/2022 at 11:00 AM, nicam49 said:

That was a shocking waste of time! (see what I did there...?)

Can you recall the make of the shocks you'd fitted that proved to be a total disaster.... and which make have you fitted now? 

Very good 😂

I just bought cheapies off eBay as I don’t plan to keep the car - replaced with Napa ones from local autofactor