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Fiesta ST Front Suspension Knock

91K views 96 replies 29 participants last post by  Riaankroese  
#1 · (Edited)
Guys, It has taken me a while to start this thread because I have been researching it for a long time with sadly no definitive result.

This is about a suspension thump noise at low speed on Fiesta ST's. If you don't have this noise its really hard to describe but its like the suspension hitting the bump stop.

If you Google "Fiesta St front suspension noise" you will get 100's of results. I have read almost all of them, even foreign language ones.

If you have this noise in your FISt you will know exactly what I am talking about, if you don't, you are very lucky.
You also may actually have this knock and think that it is normal. Its not.

Below are the facts as I have researched and my own experience.



  • Ford seems to be aware of the noise but does not acknowledge it exists.
  • It only appears at low speed <20ks
  • It only appears to be only when wheels are straight, but this is not 100%.
  • It is NOT a metallic noise but a very loud thump like suspension is bouncing up and hitting bump stop
  • It only happens on one side, either left or right side (never both) but left side is far more common.
  • It reduces in loudness if someone is in the left seat (but not much).
  • It cannot be felt through the steering.
  • It only happens once, needs 100 metres of flat road before it happens again, no matter how rough the road is in between.
  • One German forum post said he still had the noise after fitting coil overs.
  • Noise is there since new it neither gets worse nor better over time.
  • It sounds like Subaru "shock knock" but apparently is not. See note below for explanation.

My dealer has had my car for 4 days to look into this along with a few other issues. At first the Chief Mechanic went for a test drive and told me the noise was the Sub woofer under the seat. (WTF) I removed the Sub, back to the dealer again. This time the Service Manager went and identified the noise even before we left the car park (my god what is that, he said ?). The dealer replaced the front left shock absorber mounting bracket (but not the absorber or strut). and said they fully checked the suspension. At least they said they did, I have no way of proving it.

The noise is still there. So I have given up on the dealer.

This is a particularly annoying noise as you tend to deliberately listen for it.

My point now is maybe someone on this Australian forum can shed some light on it or make others with the noise aware and maybe have a solution.

I should point out the suggested ideas of what is causing this noise are endless, really looking for some constructive thinking.

Note:- Subaru "Shock knock" Subaru WRX and STI's had a known fault called shock knock. The shock absorber is fitted into the strut tube with a high density grease. Overtime this grease would dry out and the shock would flex slightly in the tube hitting the side of the strut tube and making a knocking or thumping noise at low speed. The solution was to simply refill the strut tube with new grease. Problem solved.
 
#6 ·
The Strut mount is thought of as a common cause of the problem. And yes, guys get it replaced like you, then also like you the noise returns.

So I'm curious does the noise occur when hitting something like a pot hole or man hole cover or is the issue when driving on on plain flat road? My suspension does definitely feel like it bottoms out on pot holes etc but I've never noticed an issue on flat road at low speed like you speak of. Any dash in cabin a/v footage?
imo the factory struts are not brilliant and have been weighing up changing them for a better setup. Koni SRT.t or BC coilovers are two on my short list.
MOFist you defiantly have the noise. Your comment "My suspension definitely feels like it bottoms out on pot holes" proves it. I may have not made it as clear as I should have. Does NOT occur on flat road, but yes hitting manhole cover, even a catseye or an expansion gap in the road and it sound like the suspension is going to fall out.

When I drive out of my driveway on to the road, a 25mm (1") drop the klunk is very loud.
 
#5 ·
So I'm curious does the noise occur when hitting something like a pot hole or man hole cover or is the issue when driving on on plain flat road? My suspension does definitely feel like it bottoms out on pot holes etc but I've never noticed an issue on flat road at low speed like you speak of. Any dash in cabin a/v footage?
imo the factory struts are not brilliant and have been weighing up changing them for a better setup. Koni SRT.t or BC coilovers are two on my short list.
 
#7 ·
I find everything on suspension/chassis is very noisy in general. Gearhshift, steering, struts, brakes squeal. I have chocked it up to the stiffness of the whole setup but the Ford dealer was not helpful at all, and honestly I also now believe that I have a really early production number. Keep meaning to check the vin#
 
#11 ·
One more thing I was going to mention is why not get another demo FiST and take it for a test drive over the same area of road.
This will at least settle your mind on if it's 'normal'.
 
#12 ·
I have actually done that 3 times. Once, a demo from a dealer, no noise. Second from a a fellow FIST owner in Harboard. He has the noise. Third a demo from a dealer on the gold coast whilst visiting my dad. It also has the noise.

A lot of you guys have this and think its normal. its not till you drive a car without it you realize you have a serious problem.

Chris
 
#13 ·
Well if the dealer thinks it's normal then I guess we're banging our heads against the wall going there. Me personally I'm hoping to go to the dealer once a year max. I mean of they can't do my oil change properly then i don't have a lot of hope for their competence.
I'm curious if light can be shed on this issue so we can rectify it ourselves if need be without fuss.
 
#14 ·
Don't recall ever hearing that noise on my fiST. Mine is a 2013 and has done 11,000km's
 
#16 ·
My FIST is August 2013 build.

Pedal grip is Alloy with raised black rubber round dots about 5mm in diameter.
 
#19 ·
i think mine makes this noise but only when going on reverse and it makes the sound like 2 times on the left side(drivers side)
As I said guys in my first post if you do a google search "fiesta ST suspension knock" you will get 100's or results. One forum even has an online survey, to gather details of this world wide problem.

The frustrating issue is some vehicles have no clunk at all and others sounds like the suspension is about to fall out. And its only pretty much ever on one side of the car. mostly the left side.

The consensus is its a design problem, but these cars are assembled by robots, they are all the same. Design problem does not make sense why some have the clunk and others not.

People who have this (like me) it has existed sine the car was new.
 
#21 ·
This problem has never been described as a "squeak" and it (from my research) never develops. It there from brand new, and does not get worse or better over time.

Squeaks in suspension are usually a bit of grit on the shock absorber sharft. Jack up the side you think is the problem, remove the wheel and spray WD40 liberally all over the spring, spring seat and chrome shock shaft. That should fix the problem if not then its one of the suspension rubber mounts. The process to identify which one is the same. spray the rubber mounts with WD40, the squeak should go away but it will probably come back. Then you have to spray each mount one at a time till you identify the squeaky one. You can then have that one replaced or buy some anti seize molybdenum disulphide spray which will get into the rubber and stop the squeak.
 
#23 ·
So are these issues that are non US st
 
#24 ·
No it is US and non US alike. In fact if you do a google search you will find the Majority of posts about this noise are on US forums


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#25 ·
And Ford dont want a bar of it right? Me thinks its pointing to design flaw. Maybe a weight distribution issue? Some of the complaints online mention the sound goes away with a passenger riding along. Perhaps when its just the driver the lateral weight distribution is uneven enough to cause the strut to behave differently thus flexing somehow?
 
#26 ·
If you read a lot of the various posts on forums you will find that pretty much every suspension part has been replaced without fixing the fault. The latest thinking is something wrong with the strutt tower itself. Or, the area on top of the tower where there are a lot of parts and bits and pieces in very close proximity to the top of the tower. But really at this point no one seems to know


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#27 ·
I have this issue but only one point differ. It happens when the wheel is turned.
When accelerating or slowing down ( from or to a stop, normally driving), turning and hitting a crack or small pothole, a very audible thunk is heard but no feeling in the steering. Sounds like something is loose and will fall.

I did go to the dealer and they changed the upper strut mounts. The noise returned within a week

Nothing seemed loose when I changed my tires but I'm no professional mechanic. Engine mounts are all solid

I have a dealer appointment in two weeks and will try to get a tech along for a ride.

:mad:

PS, I'm not from australia
 
#29 ·
Can you please read post #8 from "ford Service" Meghan and PM her about your noise problem. I PMed her and she was keen to help but could only help US owners. There may be an opportunity here for you to actually help many of us with this problem as this is the first time a "ford" representative has been interested to help.

Please feel free to PM me at any time.

Chris
 
#28 ·
Thought I had a clunk issue in the back of the car... After poking around a bit I found it to be the
spare tire cover board (cargo area floor). I used some velcro to hold the board down firmly, and
that rear noise is gone. I'm thinking about 'latching it down'. Gotta figger that one out.

I've heard no noise from up front to date, save the shift linkage clunking about. (Which Ford has found to be "normal")
The suspension does hit hard in a pot hole, but the limited travel in the suspension might be letting the the suspension
hit its stops. I have to rotate tires, so I'm going to look the stops when I do so... If it IS the stops bottoming out, it will
certainly show.
 
#30 ·
Although this noise does sound and is a bad as the suspension bottoming out it is not. If you place a cable tie round the shock shaft you can easily measure the amount of suspension travel you are getting as when the shock compresses the cable tie moves up than stays at that position. In most normal driving the tie never gets anywhere full travel.

Chris
 
#41 ·
Actually, I am not US resident but I did contact Kwasi from @FordServiceCA

I work away from home and my appointment is only on may 20th...I'll keep everyone posted

I'm not seeing a message from you, mYsTiCfAc3. Looks like it didn't make it into our inbox. Please send us another PM with the details, including current odometer reading, VIN, dealer, your name, and your best daytime phone number. I'll look into this and see how to best assist.

Mariel
 
#34 ·
It has never really been described as a vibration. It is a loud low frequency thump totally out of character with the speed you would be doing.
 
#38 ·
I think we are forgetting that the suspension and indeed car are designed and assembled by computer. The past few comments may be true if all STs had the suspension noise but not all do. Thus it must be a faulty component or assembly production spread. E.G one part too close to another


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