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Strange noises from my Fiesta 1.6: Ford gives incorrect diagnosis

We decided to get a second opinion on this, and took the car to an independent garage. After examination, nothing looked to be out of order, something later confirmed by the mechanic.

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So, this was a somewhat confusing situation overall. The strange noise I mentioned in my earlier post was diagnosed by Fortune Ford Tolichowki as a failing power steering pump. Furthermore, another sound, somewhat like a rattle, recently appeared from in front of the passenger cabin (around five days before the time of writing). This was strange, as it reminded me of the time just before replacing the suspension, but to a lesser degree. It occured over rumble strips and poorly leveled surfaces.

Fortune Ford also said that several components of the rear suspension required replacement. That was a red flag, since we got nearly the entire suspension (front and rear) replaced just over a year ago. Furthermore, the power steering pump would supposedly cost over 30000 rupees, but due to Ford's exit, would prove to be difficult or impossible to source.

None of this added up, as there were absolutely no abnormalities in steering feel or behaviour at any speed whatsoever. No noises while turning the steering wheel, no squeaking or humming sounds on a cold start and no fluid puddles underneath the car at all. The effort required to turn it was normal, so was the way it weighs up with speed. As for the second noise, I was very concerned, since that would either mean that the replacement suspension was of poor quality, or that being driven over Hyderabad's rumble strips seriously took a toll on the suspension. But, giving it a little more thought, I realised that nothing seemed to be out of order with regard to the suspension's behaviour in general. Stability was excellent as ever, so was turn in and composure during cornering.

Hence, we decided to get a second opinion on this, and took the car to an independent garage. Unfortunately, we were somehow unable to replicate the noise at all! The car was still put up on a lift and the underbody, especially the area around the front wheels, was carefully examined. To my untrained eye, nothing looked to be out of order, something later confirmed by the mechanic. To the contrary, the suspension was stated to be in good condition. Hence, a failing suspension was fully ruled out as the cause of the second noise.

As for the first noise, a detailed description of it lead to a tentative placement of the blame on the brakes; something that Fortune Ford also did during the service and claimed to have fixed. The power steering pump was fully ruled out as a cause. The steering wheel could be turned lock to lock while stationary without any noises and vibrations. As for the brakes, the wheels turned freely when rotated by hand, and careful examination of the braking system proved to be unfruitful. The car was certified to be in perfect mechanical condition.

However, both noises still occur. What could be the cause of this? I am stumped as to the first noise, and can only roughly locate the second one to be coming from the front of the passenger cabin. It could be as benign as a dashboard rattle or as serious as major mechanical part that is on its way out.

Anyone who has experienced this? And does anyone know of competent independent garages that can diagnose and deal with discontinued Fords? Help would be welcome.

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