Steering Rack Update + My Last Ever Alfa

[top_man_eldo]

Afternoon all,

After making a few posts this week about getting my new steering rack fitted, I have finally had it done as a last resort to cure the constant rattling noise that was coming from under the car. Has it cured it? Nope.

Hence this will be my last ever Alfa Romeo. I have owned the car for around 14 months, and in the last 14 months have spent more maintaining it than what I paid for it. Yes, Alfa Romeo have all the character and charisma (and whatever else you get that works with them) that other car manufacturers don't, but is it really worth all the hassle?

Whoever reads this, please don't let it put you off buying an Alfa or whatever, I may have just brought two bad ones. But I drove down to Dorset yesterday in a 17 year old Lancia Delta HF Turbo. Done it no hassle, a bit noisy from the exhaust, but that is a car with character. It is also a car that I am quite confident could use everyday, without bits falling off of it, rattling noises every 100 yards, the thought of the airbag light coming on! etc etc etc.

I'm writing this now laughing, but it's not really funny at all. My Alfa is 8 years old and people with MK II Escorts have probably had less hassle with their cars than I have mine. All I wanted to do was to cure a rattle from the front suspension, I cannot possibly replace any more bits, probably because there are no more bits I can replace. Having a steering rack fitted was a last resort at getting rid of this noise - the garage told me and even pointed out to me that there was play in the rack, but after fitting it, no different at all. Steering feels better, but rattling is still there. Drop links were fitted 10,000 miles ago - do they really wear out that quick and could it be them that need changing, yet again?

If anyone has any idea on how I can fix this, please let me know, no matter what it is, I am completely desperate now to fix it! My other posts go into detail about what I've done!

[sa155ae]

Originally Posted by top_man_eldo

Afternoon all,

After making a few posts this week about getting my new steering rack fitted, I have finally had it done as a last resort to cure the constant rattling noise that was coming from under the car. Has it cured it? Nope.

Hence this will be my last ever Alfa Romeo. I have owned the car for around 14 months, and in the last 14 months have spent more maintaining it than what I paid for it. Yes, Alfa Romeo have all the character and charisma (and whatever else you get that works with them) that other car manufacturers don't, but is it really worth all the hassle?

Whoever reads this, please don't let it put you off buying an Alfa or whatever, I may have just brought two bad ones. But I drove down to Dorset yesterday in a 17 year old Lancia Delta HF Turbo. Done it no hassle, a bit noisy from the exhaust, but that is a car with character. It is also a car that I am quite confident could use everyday, without bits falling off of it, rattling noises every 100 yards, the thought of the airbag light coming on! etc etc etc.

I'm writing this now laughing, but it's not really funny at all. My Alfa is 8 years old and people with MK II Escorts have probably had less hassle with their cars than I have mine. All I wanted to do was to cure a rattle from the front suspension, I cannot possibly replace any more bits, probably because there are no more bits I can replace. Having a steering rack fitted was a last resort at getting rid of this noise - the garage told me and even pointed out to me that there was play in the rack, but after fitting it, no different at all. Steering feels better, but rattling is still there. Drop links were fitted 10,000 miles ago - do they really wear out that quick and could it be them that need changing, yet again?

If anyone has any idea on how I can fix this, please let me know, no matter what it is, I am completely desperate now to fix it! My other posts go into detail about what I've done!

Are you sure it's not the captive nut symptom in dashboard Fun starts @ 3000!

[top_man_eldo]

No this is underneath the floor, like footwell area. You can feel it through your feet!

[ricardo 83]

hi top man i also have the same car and havin the same problems as you it a constant rattle an clunkin noise,i also have spent loads on repairing it. no one said to me it would be expensive owning an alfa

[Phear]

Too many posts for me to look back through but what about engine mount? There is a central engine mount situated in the middle roughly under the center of the dash. If that were shot i'd expect you'd feel it through the floor.

[sa155ae]

Originally Posted by top_man_eldo

No this is underneath the floor, like footwell area. You can feel it through your feet!

Ah now you come to mention it my mate has this on his JTD, he keep asking me to have a look at it

[sa155ae]

Could it be the anti roll bar bushes!

[neileg]

Sounds like antiroll bar bushes to me, too. I believe that pattern drop links could go in 10k but I've no first hand experience.

[Phear]

Originally Posted by sa155ae

Could it be the anti roll bar bushes!

Hope to god its not, hell of a job and would have been best to do it whilst changing the steering rack. There is a "fix" for worn ARB bushes tho, that involves screwing wood screws into the bushes to tighten the grip on the ARB, don't know how long that would last tho.

[symon]

You did fit new anti roll bar bushes didn't you?

Looking at your other post you look to have replaced almost everything else.

Did you check the other engine mounts other than the top one?

And I don't mean to sound funny but are you 100% sure it is coming from the front and not from the rear? It sounds like it could be the tie?panhard rods? The forward part attaches just behing the drivers seat. Obviously the only way you will feel any clonks is through your feet on the floor in the front.

It is also possible to get clonks from new front wishbones if you re-use the original retaining bolt on the lower ball joint.

Lots of people with fiat coupes have had this problem. The method of ball joint retaining is the same..

[gazza82]

Originally Posted by Phear

Hope to god its not, hell of a job and would have been best to do it whilst changing the steering rack. There is a "fix" for worn ARB bushes tho, that involves screwing wood screws into the bushes to tighten the grip on the ARB, don't know how long that would last tho.

Self-tapping screws would be better ... and less likely to rust as quickly.

[top_man_eldo]

OK Here's What I've Had Done To The Car In 14 Months....

Top wishbones replaced
Lower wishbones replaced
Shock absorbers / springs replaced
Anti roll bar replaced
Droplinks replaced
Exhaust mounts replaced
Suspension top mounts replaced
Top engine mount replaced
Track rod ends replaced
Brake pads replaced and discs replaced

...oh and today a new steering rack as well.


I have examined the engine mounts, they are fine, that was about 2 months ago. They are still OK. The shock absorbers and springs were swapped for Konis (as a kit), but was rattling and banging before these were fitted !

Oh, and to top the lot, I have the airbag light on and the gearstick now won't centre / go into 6th gear.

[top_man_eldo]

OK UPDATE !!!!!!!

I have just taken the Alfa out for 5 mins. I went down a quiet, straight road and took it up to 30mph. I violently grabbed the steering from left to right quickly - I got thrown about a bit, but found that when the car is weeving, I'm getting a knocking, so something has movement. Bearing in mind that the car does knock from under the front footwell when going in a straight line, but it is more noticeable when violently grabbing the steering, so something has play in it!

Any ideas ???

[ally]

No, but I've never been beaten by a knocking sound- so far. Just a shame you're in Kent as I'm in Derbyshire right now. Surely a decent mechanic could trace that noise? BTW, are you paying for incorrect diagnosis? You shouldn't be.

[ally]

Ok, the last statement was untrue. I did once not get to the bottom of a knocking sound on the rear of a 156 Sportwagon, but I didn't charge the guy, and I didn't get a proper chance to get to the bottom of it. He wasn't teed off or anything- just circumstances.

BTW, I have more confidence in my 152k 1990 75 than my 82k 1998 156. I understand why you have more confidence in a Delta HF Turbo. Hmm, HF Turbo.....
Just imagine Homer Simpson saying the last bit.

[Smaky]

After al this, I'm starting to think it's the ARB bushes too, this mechanic of yours must be pretty shabby if after this amount of time he can't pinpoint it (or he's a master con artist), But also check all your exhaust mount bushes and brackets (including the one on the lower engine mount) maybe it's the exhaust swinging about???

[top_man_eldo]

Smarky, the roll bar was changed the other week, which comes complete with the bushes. The exhaust is also done up tight.

The knocking is definately down in the footwell area, I would say if anything more so on the drivers side. But it really is difficult to tell.

With regards to the lower engine mount, do you mean this one...

[Phear]

There are 3 lower mounts, 1 under the front of the aux belt, one on the opposite side that mounts on the gearbox and 1 in the middle under the back of the engine. It is this last one that seems the most likely to me. The one under the cambelt tends to cause the engine to appear very loud, especially under load. The one on the gearbox side tends to cause the driveshaft to clonk on the suspension, noticable by rubbing marks.

[Squadrone Rosso]

Classic upper wishbone or ARB drop link knock.

[taffyjason]

I have a knocking coming through the steering column when going over rough patches, like somthing slightly loose and metallic clanging on the column, never feel it on smooth roads...sound familiar?

[AlfaLincs]

I suspect you have thrown too much money at the 'problem' without getting a proper diagnosis. Why did you not let the problem come to you by waiting to see what falls off, or becomes obviously noisier.

We've all had annoying knocks, and it pays to be patient unless it is obviously safety related. I once replaced a knocking front strut on our Skoda Favorit, only to find it was not the strut, but the rear wishbone bush that was knackered...DOH!

If its all safe and passes MOTs then just accept it until the culprit makes itself obvious. Playing what I call 'Parts Darts' and throwing parts at the car in the hope that one of them will cure it is expensive, and as you have found, very frustrating if it doesn't do the trick.

We've had our 156 about 15 months and covered over 40,000 miles in that time. Its not needed anything that any other car would not have needed, and it stands at 85,000 on the clock now.

I'd agree that a 75 is a more 'honest' car mechanically however.

AlfaLincs

[Smaky]

Originally Posted by top_man_eldo

Smarky, the roll bar was changed the other week, which comes complete with the bushes. The exhaust is also done up tight.

The knocking is definately down in the footwell area, I would say if anything more so on the drivers side. But it really is difficult to tell.

With regards to the lower engine mount, do you mean this one...

Nope, that's the gearbox mount.

http://77.251.11.230:7080/navi?MOD_C...OD=1&DRW_NUM=4 is what I mean. Also chexck the gearstick housing is still tightened up to the chassis.

[ally]

I agree with you AlfaLincs. Sometimes it is necessary to allow the fault to develop to become more obvious. This does not mean dangerous, but only to the point that accurate diagnosis is possible.

That said, with all that has been done, it does sound like it's been happening for a while.

[Smaky]

If you've been near Dover then I'd check the wheel arches for immigrants.

[StescoG66]

I have something similar too although mine is a kind of hollow noise. I had a lower wishbone done and added powerflex ARB bushes. Tightened things up no end (as did the track rods on the steering rack which was causing the play - see EB Spares Track rod (all models except GTA) - Alfa 156
This may help.