Fiesta mystery clunk

[mrnvh]

I've got a 2004 Fiesta LX 1.25 which has had me stumped since August; It's been to 4 different garages including a "halfrauds" and they can find nothing wrong.

Except there is:
Below 20mph and when the suspension unloads/drops there is a clunking noise that can also be felt through the steering wheel and the pedals. It sounds terrible on the concrete car park at work where every expansion joint will make it sound like something in the car is trying to tear off of its mountings.

But the garages have found nothing wrong in the suspension, or the engine mountings, or in fact anything even though they have experienced the clunk themselves. And it's getting worse, but I'm out of ideas now so I was hoping there may be some theories here.

To summarise;
- Low speed clunking at front driver side below 20mph.
- Found nothing wrong with suspension
- Found nothing wrong with other mountings (engine etc.)

[Dave_ST220]

Clunking is usually lower arms, is it getting worse? Normally you would see the bush is split but that can look fine & still clunk. Has a ford dealer looked at it?

[Peanut Gallery]

I agree with Dave - I had clunking and notchy steering, replaced lower arm bushes (I think) and both stopped.

When was your last MOT? - They tend to be fairly harsh with a crowbar on all suspension joints when doing an MOT. Or possibly have a look at all joints both with weight on the wheels and with no weight on the wheels.

[mrnvh]

MOT was January which had no advisories and definitely clunking then. Not taken to a Ford garage yet but lower arm bushes sound like a good starting point. They aren't split but they are definitely old rubber.

[battered]

Check also driveshaft UJs. If b*ggrd then they will clunk when you take up the drive.

[mrnvh]

For the lower arm bushes you have to replace the whole arm don't you? Doesn't look like you can take just the bushes out.

[Dave_ST220]

They used to sell just the bushes on my car but TBH as the arm needs to come out you may as well replace the whole lot (as the ball joint etc is on it which will be worn too). Not sure how bad a job it is but IMO I would get genuine Ford. They WILL cost more but they WILL last much longer. The arms on my car have now seen 100k miles (Ford uprated the bushes to be much larger, one reason I changed the whole arm).

[LuS1fer]

I would check the front springs which are prone to snapping the ends off, at the top and then reseating but they still move.
Hard to spot until, like mine, the spring suddenly rotates and tries to shave your tyre tread off.
Garages may not be arsed to spot it as you have to compress the springs to get a good look.