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Thread: Another front end clunk/rattle post....

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  1. Re: Another front end clunk/rattle post.... 
    #11
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    I'll give that a go, thanks justinpayne
     
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  2. Re: Another front end clunk/rattle post.... 
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    The distance between the caliper and the housing looks to be too large for the depth of the pad itself, so there is too much clearance above and below the pad ("above" being away from the centre of the wheel)

    If the caliper is original, maybe the surface where the edge of the pad bears is worn, or the new carrier is incorrect.

    If there is no problem there, maybe the caliper is too loose on the guide pins?
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    1996 A4 B5 Avant 1.8T engine code AEB automatic with 67,000 kms - 42,000 miles on 18/08/2020.
    VW T25 Camper, Alfa 33 1.4 ie, Alfa Sprint 1.5 QV, 2 Alfa 33's for parts.
     
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  3. Re: Another front end clunk/rattle post.... 
    #13
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    Thanks FenchAudi,

    Agreed that the distance appears too great. This was just the same with the old carrier- the thought being that it was worn and a new one would rectify. I have changed the guide pins and their rubber bushings, not sure what else I could do in that respect. The caliper itself is indeed original- perhaps wear on the pad bearing surfaces is a possibility. I'll inspect it closely again and maybe look to swap the caliper too.

    Not sure there's much left that could case that gap, unless the caliper body is somehow distorted but I can't see that, with it being a solid casting.
     
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  4. Re: Another front end clunk/rattle post.... 
    #14
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    The front brake diagrams and instructions in the Bentley manual for my car, which I assume has similar front brakes, say the following, which might be helpful :-

    "CAUTION - The inner brake pad (with expanding spring) is marked with an arrow that must point in the direction of rotor rotation when the vehicle is moving forward. Incorrect installation can result in excessive noise

    Outer pads have an adhesive with a protective sheet on the backing plate; remove this sheet before installing

    NOTE Before installing new brake pads, thoroughly clean the brake calipers (free of grease). Pay particular attention to removing any adhesive residue from the outer brake contact surfaces."


    Was all old adhesive removed, and are the outer pads stuck onto the caliper in the right position?
    I think the pads should be properly seated in the carrier, with their ends in the groove, before the caliper is placed over them and they stick to the caliper surface.

    Also:

    Retaining spring
    Insert into both holes in brake caliper housing.
    Once spring ends are seated in holes, press retaining spring under brake carrier.

    CAUTION -
    If the spring is not installed correctly, the outer brake pad alignment mechanism will not be able to compensate for wear, and increase pedal travel will result.
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    1996 A4 B5 Avant 1.8T engine code AEB automatic with 67,000 kms - 42,000 miles on 18/08/2020.
    VW T25 Camper, Alfa 33 1.4 ie, Alfa Sprint 1.5 QV, 2 Alfa 33's for parts.
     
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  5. Re: Another front end clunk/rattle post.... 
    #15
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    If the noise starts really easily I'd pad those gaps with a bit of paper, rubber or BluTak to see it it stops the rattle on a test drive. You'll know you're looking in the right area then.

    I've flipped your image to make it easier to compare with the other side. It looks like the top of the "slot" isn't straight (red box), and is binding on the part going into it. Can you put a same size drill bit or other well dimensioned test item in both sides to check spacing, parallel sides, etc?

    The spacing on the orange box and chamfered edge on the blue one look different as well. In general things don't look quite right on that casting, although difficult to really tell from a picture.

    Was the original, noisy carrier the same? Can you slot a loose pad into one or the other more easily / better?

    caliper.jpg
    ======

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