2010 mustang gt coupe, 21k miles
I have been getting a popping noise and feel on rough roads or speed bumps for a while now the car has been to the dealer 5 times for this problem and still isnt fixed.

whats been done so far in order

1st trip-blamed noise on a exhaust hanger resonating to the front end and didnt touch the car....
2nd trip diff dealer-replaced right lower control arm and screwed up alignment.
3rd trip- adjusted sway bar and torqued all fasteners and re aligned....also chipped my paint
4th trip- changed the same lower control arm as before and adjusted sway bar again, screwed up alignment again
5th trip- its in the shop as i speak and needless to say i have zero faith they will fix this car

What could be causing my issues that the tech's are not finding at ford?

 

I'll go with a ball joint...

 

They changed to lca twice which included the ball joint

 

Yes, but they only changed the right side. You didn't specify if the knock was coming from a specific side. So it could be the left side ball joint. Could also be tie rod, wheel bearing, shock tower mount, the shock itself, steering shaft u-joint, control arm bushings, rack-n-pinion bushings... the list goes on. Noises in the front end can travel, especially if you only hear them from inside the cab while moving.

Maybe try jacking the front end up and getting a large pry bar and start trying to move components around. Look for stuff moving that shouldn't be... Here is a good video with some tips:

http://www.youtube.com/user/EricTheC...34/scFbb43fwqk

Good luck...

 

Sorry I forgot to mention the noise sounds like its coming from the passenger side and resonating to the firewall an under the car.

 

Take a look at the motor mounts

 

I asked the ford tech to check the
Motor and trans mounts and he said there is no way they are bad at 21k.... I picked the car up yesterday and all they did was adjust a away bar bushing again and said all mustangs make noise...wtf
I'm going to just let my lemon lawyer handle it now screw ford

 

Just took in my 08 with the same type noises @ 20k miles.

Sure sounded like control arm bushings or ball joints. They replaced the sway bar bushings- noise gone.