Hi guys,
I'd like to contribute a little bit to the community knowledge by sharing my experiences with "strange" knocking noises coming from the front suspension.
As the weather was not very nice to us this year and it rained a lot around these parts the roads are full of pot holes and generally I think our roads in Serbia aren't up to any standard (in most places at least). Don't take it offensively, there are smooth and good roads in the country...surely somewhere...

To get back to the topic I had a similar issue like the lot of you of hearing a distinctive knocking noise coming from the front of the car when I went over pot holes and generally not even roads. The sound was more or less there when the car rolled from side to side on bad tarmac. On a smooth pavement there were no apparent sounds and the car drove smoothly at least to what I could feel and tell and I drive it a lot mostly on highways and the rest in town.

The first check up point was to visit the car optics shop to check the wheel alignment at the time when I changed the tires from winter to summer ones two months ago.
They noted that the front track control arm joint at the right side was pretty much shot (worn out) and the left side was on it's way and this could be one of the reasons. Given I like to treat the car as any member of the family (in a good way ) I took it to my "trusted" mechanic to have it checked up. It was obvious, the wheel alignment guys did not lie the control arm or wishbone was worn (note: i changed them a little bit over a year ago). No way back, have to do the job, I need the car and I like to play it safe after all we are driving the beast a lot. Changed the parts, both front control arms just to play it safe, no point in coming back cause of the left one in 6 months again I thought and I also thought this was it. Sadly, when the mechanic took it for a test spin he went immediately out to town and on the highway where there is no knocking sound heard from the front suspension.

No prob, took it back for wheel alignment, they did the job, I stood there all the while they were working on it. All is in the green and the steering wheel and other various angles have been aligned according to specifications.

I took the car for a descent 2000 km's for a business trip around these parts, and I noticed the shaking rattling-knocking sound wasn't gone. For that matter it only got worse, producing it more often.

I took it to the shop again, a little bit pissed that the rattling-knocking noise is still there and more apparent then before.
I stood beside the car during the "check up" and on the left side there was a little bit worn anti roll bar. NO worries, cheap fix maybe 10 quids and a bit extra for the mech. But then I took it for a test drive and the knocking-rattling sound was still there to my ever growing amazement, you can guess I was a little bit.
Back to the lift, mount the car and do a complaint that the sound is still there and I can clearly hear the rattling-knocking sound.

Finally, the fix comes up (at least hopefully)

The rattling-knocking noise when going over bumps and uneven road is caused by worn anti roll bar bushes. Damn, finally something a light at the end of the tunnel. I told my mechanic friend to check and double check and he tells me that they missed it so far because 1. they did not drive it on uneven roads 2. according to them it's a fairly sound piece of rubber and mounting which rarely brakes .... yea, I add to it when you drive the car only on a highway ...

Anyway, new parts ordered. Should be in by next Monday. It all is not a too expensive fix bout should make a difference.

So to sum it up, the rattling-knocking noise, at least in my case, was caused by badly worn anti roll bar bushes. All else should be fine.

Should be... Murphy is never asleep

Cheers mates, going to update the thread when the piece arrives and it's put in. Hope that clears any knocking sound.

:bang:
When somebody starts the message with this icon it cannot mean god... Exactly.

I did my usual route to my mechanic since he let me know the rubber bushes on the anti roll bar shafts have arrived. I was thrilled finally to get this resolved and to fix the cause of the rattle knock sound coming from the front of the car.
The bushings turned out NOT to be the cause after all ... damn my luck... further investigation was needed. This meant some driving around on uneven roads with two mechanics in the car listening for obvious signs or tell tales of what could still cause the knocking sound.

After the third try what was only left to check was the steering shaft and rack and pinion... Don't you know it, when the guys wiggle it around I can clearly tell that's the rattling sound I am hearing when going over bumps ... it could be felt over the steering wheel a bit as well and even through the chassis.

At the moment the diagnosis is that a complete new Rack and Pinion is needed for our Stilo. The good news is that the list of things that could cause this rattle is very narrowed down now. This wont be a "cheap" fix and I'm not willing to let myself into any compromises with safety critical systems like the steering. So at the moment I'm hunting for a brand new rack and pinion, already found quite a few used and brand new ones as well. Tomorrow we are going to try to find the proper one with good quality and that fits.

I asked today is this surely 100% the cause of the rattle, and says my mech: YES, this is the only thing left but it also had some obvious signs ... which they did not notice earlier If I might add

Anywho, shorty another go at it is coming up and I'll post the results of it. Hope this one wont cost me a fortune thou...

UPDATES: Ordered the part, it's going to cost 200 euros for the brand new Fiat rack and pinion (at least I hope it's the proper name for it in English). Another 50 eur for the mechanical work.
It should be done in the next two weeks. I'll keep you guys posted about the results once it's done.
My mechanic ensured me the car is more than derivable in it's condition since for now it's only a "small knock" (by the way which I feel through the steering wheel a bit). He calmed me down by saying, and I quote: "hah, if you'd see the stuff people drive around in, you wouldn't be so upset..." This does not satisfy me, I like to have the feeling of safety in the "tin can" I drive.

be good guys!
Zoli

Finally managed to solve the issue of the knocking noise coming from somewhere around the front suspension.
As suspected by the mechanic turned out to be the shaft of the steering column and as it later turned out a new rack and pinion was not needed. A part on the steering column was worn to a point it had started making banging noise on uneven roads and going over bumps, also had a small play in steering (what can I say, wonderful roads around these parts.... shiiiisssst ).

I finally had it fixed, the steering column had to be taken out, refurbished and now it's as good as new with an additional one year guarantee from the mechanic that did it (specialized shop for steering and parts). The whole fix cost a 100 euros (instead of the planned 250) but now no noises, smooth steering. I took the car for wheel alignment as well but that was nothing compared to the the mechanical fix.

Thought I'd update the thread. Cheers guys!

Thanks for these posts. Should be useful to other Stilo opwners.