We bought a 2004 1.6tdci zetec about 7 months ago from a local independent Ford dealer. Right from the start, there has been a really irritating clunking / rattling sound that comes from the nearside engine compartment. At first it only happened when the engine was cold but now it's all the time but it is most noticeable when accelerating from rest or pulling away from a junction turning left or right. It sounds as if the engine mountings are loose - but they have been checked! The car has been into the dealer 3 times and they have literally taken the car apart, replaced the wheel bearings and driveshaft but this has made no difference and they basically told us that we will have to live with it. Overall we are really pleased with the car but can anyone point us in the right direction with this problem?
Thank you for the reply, I thought it had something to do with the suspension, We will let the garage know and see if they will sort it out - it is driving us nuts! will let you know of the outcome. Thanks again.
We think the rattle has finally been sorted out - we got the car back after 2 weeks in the garage. This was after have a NEW flywheel, NEW clutch, NEW drive shafts and other bits and bobs. Anyway Ford suggested replacing the engine mounting as the inside pin may have been working itself loose. It seems to have done the trick!
Yup! the work was done under warranty. Apparently Ford were just as keen as us to get to the bottom of the problem.
The funny thing is I did suggest right at the outset that the noise sounded like a loose engine mounting but the garage assured me that this had been thoroughly checked (not).
Oh well at least we know half the engine is new.