AU II XR Rattle (not purge valve)

[cm29579]

Have had this problem for a few months now, and the strangest thing is, I had the EXACT problem in my '93 ED XR, and sadly, it was never traced, it just went away on its own (after a lot of rain - yet its not a squeaking noise).

Anyway, onto this one. It happens only when the car is warm, but not always (ruling out anything just hitting the body of the car). It is mainly on the front passenger side, but seems to rebound over to the middle also. The actual noise sounds like someone lightly tapping a spanner onto the car body.

The best link I can find, is that it is brake related. When the brakes are silent when coming to a full stop, the noise isn't happening while driving. When the brakes start to clunk as they come to a stop, the noise is usually happening. It happens from 15km/h to 90km/h (and probably above, but engine and road noise muffles it I guess.) The brake noise is frequent, not just coming to a complete stop, each time you pump them, they clunk (making the exact rattle noise), and they clunk when you take your foot off at lights, crossings ect.

Any ideas? Discs are fine and pads are about 5,000 old but are extremely noisy (make grinding noises already, even though not even 50% worn).

[matty220]

I had a similar problem check the upper balljoints im told its common

[peterban]

I will second the ball joints.
When mine first started I used to pull up to see if something was hanging loose as it was a real clanging noise.
Ford fixed it under warranty by regreasing them.
I think GK may have injected grease into his to stop the rattle

[cm29579]

Thanks for the advice, I read on here at some stage about ball joints being a possible cause.

That would make sense, that when it rains and there is some lubrication down there, the noise is gone. Ill get my mechanic to look at them.

[matty220]

keep me updated the same problem annoyed the out of me the ball joints dont have to be that loose or dry to start making that noice, good news is that its a fairly cheap fix i got new ones from pedders for around $250 fitted never heard the noice again. its hard to diagnose because the mechanic may inspect and they may appear fine but there not!! good luck

[cm29579]

So its the upper, not the lower? Just so I know what to ask for, as you said, they may not be able to tell just by looking at them. I might even try first getting him to inject grease as mentioned.....he is a taxi mechanic, so he works on AU's daily....he probably has done this many a time anyway.

[cm29579]

Fixed the Upper Ball joint today.....no luck. This problem is destined to be there forever it would seem.....so bloody annoying

[b2tf]

Are your exhaust manifold bolts tight?

[cm29579]

I've had everything checked underneath and nothing loose was found. Id like to look at it myself though. Its so strange....as soon as it rains, give it 5 mins for the underbody to be soaked and the noise is gone. Its probably a bush or link attached to a part that runs from wheel to wheel, as the noise rally is starting to go from side to side, as if something is moving backwards and forwards, banging as it runs out of freeplay.

[mik]

wouldnt be the aerial or something banging around under the inner gaurd?

[Linz]

Sway bar bushes?

[cookin]

hi had same problem on au2 xr6 replaced front lower control arm bushes noise gone the bushes help stabilize the car while braking hence the noise

[cm29579]

Originally Posted by cookin

hi had same problem on au2 xr6 replaced front lower control arm bushes noise gone the bushes help stabilize the car while braking hence the noise

Sounds good....but I can hear this noise at 90km/h accelerating...has been there for about 15 months now, with maybe a 2 months break at one point before returning.

[RG]

Have you replaced lower balljoints? These are the most common to go.

[cm29579]

I replaced the upper with no success....nobody mentioned lower

[RG]

The lower are the ones most common to go in Ford's. Have been since the start of time.