Polo 6n2 1.4tdi

Been driving around with the windows down and music up for a while so havnt heard it.

Anyway noticed it yesterday as i turned the music off.

I was going about 15-20mph and braked lightly and noticed a clink/clunk noise from the front end, possibly front left, not that loud, but you can clearly hear it.

But it doesnt always do it, which is confusing. It almost sounds like the pads have movement in them, but they are pretty tight and the rattle clips are in.

All the brakes were replaced with mintex pads and rotors a while ago now, but have been fine ever since, i took them off last month ish to check and re-grease (one was squeeling)

No problems braking whatsoever.

Been and checked around the suspension today and theres no movement, calipers have no movement, rears do a little but nothing major.

Only thing i can think of is that i went onto a field the other day and the enterance was a bit off road but didnt bottom it out or anything.

Anyone got any ideas?

It is always difficult to diagnose a noise that you haven't actually heard but here are a few suggestions:

Try moving forwards and backwards (1) with the brakes 'off', (2) repeat this with the brakes lightly applied. If you can only hear the noise as in (2), the problem is POSSIBLY brake related.

When you say, "The callipers have no movement," did you also check the mounting bushes and sleeves?

It is possible that when you jack up the front end to inspect the suspension joints, that the suspension moves into an 'unworn' position, making it difficult to find any movement.

Have you checked the condition of the splines and tightness of the front hubs, also drive shafts?

It may also pay to check the condition of the engine and gearbox mountings.

Regards.

Tried moving forwards and backwards applying the brakes when swapping with no result.

Calipers have slight movement on the pins, but not excessive, the caliper mount bolts are tight.

Driveshafts and CV's are fine

Wobbled engine and gearbox and nothing excessive and it doesnt do it when accelerating.

Only thing i did find is that the diff is very noisy/clanky when the wheels start to turn and stop, which I'm thinking its that.

I checked all of the bushes and they are in good condition, a few cracks but nothing major.

Also at my dads the street is unmade, so very bumpy, so gave the suspension a good test which i didnt hear anything.

I also never heard it on the way back.

Could it be that iv just started to park on a curb?

You may have hit the nail on the head when you mention the differential. It is not unknown for the rivets which hold the diff in place, to work loose.

The cure for this is to drill/ream out the holes and replace the rivets with FITTED HT bolts.

You MAY be able to verify (or otherwise) this condition by:

Putting the car in gear.

Jacking up one side of the front end.

Turning one wheel VERY gently and 'feeling' for an unexpected clunk. BUT take care not to misinterpret normal backlash in the splines/planet/sunwheels etc for this condition.

The above is probably the worst case scenario, so if you can't find any other cause, it MIGHT just be these rivets, but I would tend to 'let it develop' rather than take the drastic action of removing the diff, only to find that there is nothing wrong with it!

I'm not sure that parking on the kerb would have much effect on this, judging from the way that you describe the noise.

Regards.

Ill try that this weekend as i have to change a radiator hose.

Iv heard of the rivet problem and what it can do, the box currently in is not the original as the orig was noisy in neutral and generally crap. Iv kept it so i can get it reconditioned when i can afford it.

Thanks for your help.

Check the rear inner lower arm bolts, see how tight they are

Check the rear inner lower arm bolts, see how tight they are

Sorry, dont know where you mean?

Do you mean where the axle connects to the body, at the pivot point?

Sorry, was eating, multitasking isnt my strongest point.

Front lower arms, the rear fixing that goes directly up, through the subframe into the body.

Looked at them both and seem ok.

Cars only done 46k

Looked at them, or checked them?

Because I torqued them several times on my 6n with correct torque figures and new bolts and used to come minorly loose, i experienced a lack of steering feel around centre rather than a knock but yours could always be slightly looser

Looked at them, ill have to check.

Let me look for the torque.

50Nm + 90 degrees with the weight of the car on them

Could be cracked disc.

Doesnt do it everytime i brake, also disks look fine to me. Just gone on holiday and been driving 700 miles with no issues

I'm going to leave it a while as i can only hear it when the window is open going <20mph and the moment i touch the brakes (very slightly) it just clicks, sometimes loud ish.

I never noticed it with the other gearbox in so I'm pretty sure the diff is the cause.

Never does it without touching the brakes and only does when slightly pressing so i think its safe to assume its not suspension.

All the brakes were re-greased before and theres no braking symptoms and all the rotors look fine.