Had this knocking noise coming from the front of my Stilo for a while now, started just over a year ago but since I've just started driving it for 11 months I never bothered with it. But now I'm driving again and it is doing my box in!

I've had drop links changed and recently had it in the garage to have track rod ends/ tracking and cv joint replaced. Tracking etc done fine, but they didn't fit the cv joint I gave them as they couldn't determine which joint was at fault, all the boots are in perfect condition as well. They said the engine was rocking in the mounts which doesn't sound so good.

With that in mind I'm willing to take a gamble at it being the rear gearbox mount having excessive play and the rubber worn to nothing. But would the rear gearbox mount cause the knocking I hear? The knocking seems to be more from the middle and not from a particular side, also it is more pronounced when pulling away but it audible through the full rev range, also very slightly at idle speed.

The rear gearbox mount seems the easiest to replace myself and are cheap to buy hence why I want to try it before being robbed by a garage again.

Check that one of the baffle shields by the exhaust have not become bent (easy to happen if you drive through deep snow or water). They can knock on the exhaust quite easily.

My guess would be passenger side drive shaft.

Get someone else to drive your car and sit in the passenger seat. Listen and feel for the knock. Inner and outer cv's, most likely its the inner cv.

ive got this too. Are link arms same as what you said? Garage quoted Me 17 each & 70 labour. This seems fair as they normally rip lone women off!! Haha

For £17 each, they're likely to be drop links the garage is quoting you for.
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Sounds like drop links you're describing, knocking heard going over bumps?

Mine is more of a clunking which seems to be in sync with the rotation of the engine or driveshafts if that makes sense? I can feel it through the gas pedal if that helps?

It can be heard best when at low rpms with a lot of gas and at high rpms off throttle say 4k and lift off

Because yours is engine-speed-related, Mark, it must surely be the engine mounts, such as the torque reaction mount bolted to the subframe underneath (transmits the knocking into the floor). That's an easy one to take off and inspect. JTD versions have two of these, I'm told.

-Alex

Thanks Alex, I'm hoping it's that mount you mentioned - does look the easier of the three on mine to remove. Hopefully I can remove it today at my mates workshop and take a look. I should add that the rear mount on the gearbox looks to have taken a whack at some point as there is a huge gouge taken out of it on the bottom, not sure if this would affect the sturdiness in any way though.

Thanks for the info Alex, took the Stilo down to my mates workshop today and removed the torque reaction mount easily enough and upon inspection I noticed the rubber bush has work pretty badly, mostly at the section of the "eye" end of it (if that makes sense?) on the subframe mount. It's split mostly round the rim of this area also and the free play is pretty bad!

It's been refitted for the time being, now I definitely know it's that mount that's gone I'll order it and change it later in the week. Glad it wasn't one of the main engine mounts as the garage were suggesting - saved myself the hassle and money taking it in tomorrow to be looked over. Hope this new mount will solve it, I'll post back later next week wether it solves the knocking noise or what.

Just to update on this little niggle I've got...

The new reargearboxmount arrive today. Managed to fit it as well. The result: the clunking noise has reduced a fair bit and theengine response is a bit tighter. The noise still lingers though, mostly at high rpms. I can make the noise when the car I'd parked, handbrake on and ease the clutch in in first gear, eventually the clunking starts. Does that help? My unclelisened to the clunk as icons the above and he said it sounded as if it was coming from around the alternator area? :S

Any advice where to look next? The engine and gearbox rubbers are in good condition

do you know if you have too much play in driveshaft joints..before i replaced my driver side inner driveshaft tripod joint i used to get clunck when putting intop first gear and if changed into reverse when stationary.,,.this clunk I no longer have after fitting new tripod on inner drivers side driveshaft..althouugh other symptoms were vibration at any speed over 40mph this vibration has gone also now smooth gear change and drive i did think it was engine mount related in 115 jtd m/w and vibration was more on passenger side although was driver side inner joint that was worn..may be worth a look see how much play you have in driveshafts

Sorry that the clunk is still there

I'm starting to suspect the clutch - perhaps its centre springs are loose. No dual-mass flywheel on a 1.2 but that would have been a likely cause.

Open the bonnet and have someone observe while you load/unload the drivetrain (brakes on, gear engaged, clutch applied and released). If the clunk is still in time with engine movement, then perhaps there's still a weak engine mount in there. If the engine is no longer moving around, then we have to suspect something in the clutch or possibly the driveshafts (even in neutral, there is a slight torque exerted through the gearbox - wheels of a raised car will always spin with the engine running). Perhaps a driveshaft inner joint is loose.

-Alex

The new rear mount has helped to a certain extent.

I really don't to be suspecting a clutch issue now. I had the clutch/ bearing replaced in august 2011. I drove the car till December 2011 and I've only just started driving it again a couple weeks ago, it's had barely 4 months use!

Thing is that I had it in the garage early last week for them to check all the driveshaft cv joints and they have said there is no free play in any joints and all the boots are ok.

I did as you suggested earlier Alex, my uncle detected the noise and says it was coming from the alternator area.

Any way to check the engine and gearbox mounts? The rubbers on them look in good condition at a glance

Finaly! I've found the cause of the knocking noise. The exhaust has been hitting off the front subframe just where the flexi is, since I got a Punto decat manifold the mid didn't meet with it so I got a section of pipe fitted to bridge the gap. Like on the standard exhaust it required to be pressed down at the top of the pipe to clear the subframe. Obviously there is still a clearance issue so I might remove it myself and stick on a vice if I have time.

Wish I checked that first, I've now wasted money on a new gearbox mount, engine mount and cv joint lol but at least the rear gearbox mount needed to be replaced anyway.