[RESOLVED] horrible sound from front of 2gnt while braking

[Locke]

Hmmmm... Ive a 2gnt wholly stock. Just recently, i noticed this horribly loud clacking/popping/grinding sound from the front.. Well, i think it is the front passenger side, but it is so LOUD it is difficult to tell for sure front or rear, left or right.

It only seems to happen while gently letting off the brake at speeds under 15.

Assuming a brake problem:

I checked the brakes, both sides on the front. No wear on the guides, guides are straight and lubed, pads are new, caliper braket is secure. The rotor is warped, from 0.946 to 0.941. I doubt this is my bane. Neither caliper piston is stuck or biding.

Thinking perhaps rim mounting error:

I polished the mating surfaces of both the rims and the rotor hats with 200grit paper, removed the crud from the hub center, and the like on the rim. Tightened the rim down in a star pattern in steps, using a torque wrench for the final couple passes.. Im putting it at 105 ft/lbs (im not sure exactly where it should be, but ive never had a problem with 105 ft/lbs before). Rim appears to be mating evenly all around.
Tires are about half worn, and all dependably hold 32lbs are air. They are without abnormal wear (no cupping, edge wearing, feathering, etc..)

Looking into the suspension:

None of the bushings are broke or damaged, and _seem_ to be tight enough. There seems to be no play in the balljoints, though the upper control arm balljoint, i got an extra eighth turn out of the nuts (both sides). Springs are not sagging, not broke, and are seated correctly. All the fasteners are tight.

The wheel bearings are fine.

The passenger side outer tie-rod end is going. While moving the knuckle side-to-side, im getting, maybe 1/16" lateral movement .

The sound does not happen when applying strong even pressure, or while linearly icnreasing pressure. Only while gradually letting off the brake while moving at under 15mph.

I do not feel anything in the steering wheel, or any pedals. It does not seem to matter whether or not i am using the clutch or not. I do feel it in the floor, though.

Also, while applying the brake and slowly turning right into a bump (a gravel, pitted alley, for instance) while the car is clicking and popping away, it feels as though the passenger front tire is going to cave in under the car.

The steering returns to center on its own, with no problem, and rides nice and straight (letting hand off wheel at any speed).

I did no work to it prior to this happening. Most recent work was brakes, which i only replaced pads, about 8 or 9 weeks prior to this happening.


PLEASE somebody, ive done about everything I can think of myself, and rather than replace all those expensive balljoints, or take ti to a shop (alignment shop will be my last resort) Ive run out of ideas.... Thanks...

(p.s. sorry about the novel. I wanted to relay as much information as possible)

 

[1badtsi]

sounds to me like you have a loose lower control arm, get under there and tighten them up/ replace bolts, and let us know what happens

 

[Auto RS T]

Maybe the pads are trying to climb up the rotor, are they tight within the caliper mounting bracket? This is the only thing I can think of going off of your novel, (which I think is great in a case like this). Maybe the pads dont fit exactly like the originals. Are there any shiny rings around the rotor? Maybe has something to do with the backing plates. You have checked everything it seems like. Did you check the suspension with the control arm unsprung? If not it could be putting pressure on the balljoints making them seem to be ok, but when you compress the spring with a jack and put a bar under the tire pullimg up on the bar you may have movement in the balljoint area. Is this how you tested the balljoints?

 

[Defiant]

Have a front-end shop diagnose it. The front with all its steering and stuff is kind of important.

 

[Locke]

All the fasteners are tight.

The pads are cheap Wearever Gold. The rotors are glazed, so cannot see anything spectacular or obvious. I sanded the glaze off the rotors when i changed the pads.

The backing plate has no wear o it, and seems perfectly straight. the gap around is perfect.

I did not relieve spring pressure when checking the balljoints though. Ooops. I will try this tonight or tomorrow.

I will have a shop look at it if/when i cannot figure this out. I will have a shop look at it anyways, after I figure it out, to check things and align it.

I really appreciate the input guys. Thanks. Ill keep you all updated.

 

[Locke]

Whoops, sorry guys, I never got back with the solution.

The pad shims were not completely tight, a tab had broken off. There was also quite a bit of flaky rust on the surface of caliper pistons that mate against the pad shims.

New shims and sanding the rest of the rust off completely solved the problem.