Thud / Clunk While Driving Over Bumps

[derekod]

I am experiencing a knocking sound similar to drop links at times on bumpy roads and I am starting to question myself as to whether if this noise that I hear at present is after getting worse after doing some repairs on the car.

 

History of work done so far:

 

I have replaced front struts and mounts with KYB ones, as one side was grinding.

I replaced the upper spring plates afterwards as they were worn oval and had cut into the original strut.

I then replaced the KYB upper mounts with Meyle HD mounts as the their appeared to be to much end float ant touching the upper body of the car.

I have replaced both inner tie rod ends with meyle ones as there was play in one side and new boots as one was split.

 

Previous to carrying out the above work I noticed that I was getting a slight clunk while pulling away in first gear from the left front which was not present going through the rest of the gears which I put down to play in the outer cv joint, and seeing as I use to get low speed wobble after lowering the car down after being jacked up I put that down to the inner joints.

 

I replaced the front roll bar bushings as there was little play felt in them, which showed a lot of wear in them when replaced.

 

My noise is still present over bumps, I can not feel any play in the drop links but they have not being replaced.

I have checked the lower ball joints for play, nothing noticed.

I have replaced the lower wishbone bushings on both sides.

I have checked the tightness of the subframe bolts and steering rack.

 

I have just replaced both the front drive shafts with J&R ones (Which I was hesitant but the price was good).

 

My noise is still present but maybe not as severe.

 

I have noticed that there is still some lateral play between the driveshaft and outer cv joints on the car that will cause a noise heard underneath.

How much play is normal for the Galaxy if any should be allowed.

 

I have yet to drive the car at motorway speeds to see how the car drives with the new drives.

 

 

Advice welcome.

 

 

 

[gregers]

just a thought,lift bonnet,grab hold of the engine and see if you can move it?

im wondering if its the gearbox/mount thingy(cant remember the actual name)?

[mikej]

Unsure which model you have but for what it's worth, in my own experience (11 years ownership and 200K plus) if your steering feels a little vague, wondering etc i have always found this to be worn track rod ends, provided your tyres are good of course, changed half dozen over the years. As far as knocking goes couldn't really say unless i drove it, mine went through loads of drop links in the early days, various cheaper makes until one of my mechanic friends told me to bite the bullet and pay Ford prices for the originals and i wouldn't have to keep replacing them, never a truer word said, been on for five years with not a single issue. The way i used to diagnose the links was to drive very slowly over a rough bit of road, if a continual knocking could be heard at slow speed it was always drop links for me. The official name i believe for the gearbox mount thingy lol mentioned above is the roll restricter, changed one of those too, if you accelerate sharply in first or second then quickly remove your foot from gas you would feel the engine move, you can't mistake it, you would feel it in the clutch peddle too etc, put handbrake on put in first a dip the clutch you'll feel it move. It's normally the rubber worn but in some cases it's been known to snap, you would notice i assure you. Best of luck..

[BrianH]

I am experiencing a knocking sound similar to drop links at times on bumpy roads and I am starting to question myself as to whether if this noise that I hear at present is after getting worse after doing some repairs on the car.

 

History of work done so far:

 

I have replaced front struts and mounts with KYB ones, as one side was grinding.

I replaced the upper spring plates afterwards as they were worn oval and had cut into the original strut.

I then replaced the KYB upper mounts with Meyle HD mounts as the their appeared to be to much end float ant touching the upper body of the car.

I have replaced both inner tie rod ends with meyle ones as there was play in one side and new boots as one was split.

 

Previous to carrying out the above work I noticed that I was getting a slight clunk while pulling away in first gear from the left front which was not present going through the rest of the gears which I put down to play in the outer cv joint, and seeing as I use to get low speed wobble after lowering the car down after being jacked up I put that down to the inner joints.

 

I replaced the front roll bar bushings as there was little play felt in them, which showed a lot of wear in them when replaced.

 

My noise is still present over bumps, I can not feel any play in the drop links but they have not being replaced.

I have checked the lower ball joints for play, nothing noticed.

I have replaced the lower wishbone bushings on both sides.

I have checked the tightness of the subframe bolts and steering rack.

 

I have just replaced both the front drive shafts with J&R ones (Which I was hesitant but the price was good).

 

My noise is still present but maybe not as severe.

 

I have noticed that there is still some lateral play between the driveshaft and outer cv joints on the car that will cause a noise heard underneath.

How much play is normal for the Galaxy if any should be allowed.

 

I have yet to drive the car at motorway speeds to see how the car drives with the new drives.

 

 

Advice welcome.

 

The brake caliper if loose can make a noise very much like a failed drop link (it can be loose on the bracket that attaches it to the hub), no idea on the play issue. Also you've changed the ends, its possible to have worn tie rods/track rods as well, these are a seperate bit that can be replaced if so. These aren't quite so easy to test by yourself, best to get someone on the opposite wheel to brace against and see if it moves, though wouldn't expect it to make much of a noise at this.

[derekod]

Just to provide an update.

I removed both drop links to eliminate them and there is no play in the roll bar and the noise is still present.

 

There is also no play in the outer tie rods or bottom ball joints.

 

I have tried hitting the tyre with a rubber mallet and have heard nothing obvious.

There is no excessive play felt in the engine trying to rock it back and forward.

 

I could not feel any excessive play in the callipers but the pads are worn down close to the wear sensor so there is probably less of a hold on the slider bolts to stabilise them, so I will check these out next.

 

 

Following that it will be to try and check the gearbox mount on the passenger side. 

[derekod]

Just providing another update on this issue, I finally got to the bottom of what was the cause of the knocking sound and is something that can easily be overlooked.

 

The sound was actually coming from the brake pads sliding up and down within the bracket and could not be heard by hitting the calliper with a mallet, they were a Ferodo brand and I had used them before with no issue and have always being lubricated.  It was only when I separated the calliper  I could notice the obvious play so I just tightened them up by using a dot punch at the retaining ears to try and spread the metal a little until it is time to replace them.