Knocking noise over uneven surfaces

[DanDotor]

Looking for some advice, I have a 2009 XC60 with 207k on the clock, car drives well but 2 weeks ago a fairly loud knocking noise coming from the front left/middle started to occur when going over small bumps and uneven road surface. The first garage I took it to said they could not find any play in any element of the suspension etc. The second garage has also failed to find any fault but thinks it could be shock absorbers as one of them does make a knocking noise when going over speed bumps. Apparently they are prone to an internal failure that can create a knocking noise. They cannot guarantee this will fix the issue and it's essentially a £450 gamble, they have suggested that if this does not fix the issue they will change the anti roll bar bushes. I had the rear trailing arm bushes replaces about 60k ago and the sound is somewhat similar, its a hard dull knocking noise. Any advice would be greatly appreciated.

[SeaShell]

Check the front drop links. They can make a horrendous noise even with little obvious play.

[SeaShell]

https://www.eurocarparts.com/p/moog-...link-632590297

[L80YLE]

Hiya, just wondering if you resolved the knocking issue? My 2015 XC60 has a knocking issue on the NSF which still remains after changing the strut mount last weekend. I’m now thinking the internals of the shock absorber have failed?

Also has anyone got information as to the correct location of the strut mounting alignment tab?

[DanDotor]

Yes, I got the shock replaced but the noise continued, what fixed it for me was so obvious I was shocked that neither garage I took the car too thought of it. I simply lubricated the shock strut by getting some WD40 directly onto the strut, had to lift up the dust cover. Shocking that they didn't think of this after 3 separate trips to 2 different garages.

[Whyman]

I had a knocking noise from nsf end.

Turned out to be 4 in piece had broken off the bottom of the front spring. New spring cured it.

[L80YLE]

I had it stripped last week and found no obvious issues. Changed the top strut mounting for good measure but made no difference to the knocking. Not sure WD40 would resolve as it sounds like the wheel is coming off!

[DanDotor]

Apologies, my WD 40 fix was actually for a creaking noise the new shocks made. The original knocking noise that I mention in my original post was fixed by me insisting both shocks were changed. Both garages were unable to find the noise but it was the shocks.

[L80YLE]

Great thanks I’m going to change out both shocks for Bilstein B4s because I’m certain the NSF has broken down internally.

[Jaddak]

OK, so is a bit of a thread revival - did you ever get to the bottom of this knocking?

Listed a shock on eBay mentioning knocking to find a few others reach out with the same issue.

MY HISTORY with a 2016 XC60 D5
- Had a knocking noise in late 2021 & garage found a broken spring - 2 new front springs at independent, knocking continued
- Top mounts changed for KYB & as car was on +70k changed all shocks to Koni Special Active at independent - knocking continued
- Took to a MOT place with a specialised testing rig which said issue was near the top of the strut
- Then to Volvo main dealer who had for 3 days, where £500 later & new OEM top mounts told issue was with the winter wheels I had on the car... but wasn't
- Whether it's summer OEM or the separate winter set I have, knocking is still there
- New Drop links & front wishbones fitted, knocking continued
- Advised koni shock may be at fault, so obtained another & knocking continued hence why just one for sale here https://www.ebay.co.uk/itm/134759862836
- I even took it to another Volvo garage with more experience of older cars... yet they too were mystified & to their credit did not charge for investigation

Am told everything's tight, no movement... yet there's still a noise

Have spent a fortune, any further suggestions?