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Focus Titanium with 25,000 mile. On backing up going forward when turning steering wheel almost to the end point, either left or right. I can hear an audible thump or knock. I can also feel it under my left foot just to the left of the brake pedal. The inner and outer CV boots are intact - no splits or leaks. Car tracks very well - no pulling. 90% highway driving. Anyone else notice the same?
 

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Is it on reversal or at the end stop?

If it's on the reversal it's rack rattle (just a noise), its caused by the unloading and reloading of the ball nut when you switch directions.

If it's at end stop, and sounds like a ping, then its just you touching the mechanical end stop and you hear a metal to metal noise.

Both, normal, and actually quite common on EPS rack based systems.
 
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