2nd Gen Non-Engine/Transmission Brake Caliper Rattle??? Driving me crazy

[SKuyper]

I've got a rattle in the right front brake caliper area on my 98. 5 2500HD 4x4, I can't seem to figure out... On a rough gravel road it rattles and if I touch the brakes it stops making racket immediately... let off the brakes and it starts again. I've replaced the pads recently and tonight I replaced the caliper hardware. . rubber/plastic bushings and new bolts and slide tubes... It didn't fix the rattle. What else could it be that makes noise like that and quits the second you touch the brakes???? I did put the truck in 4x4 and jacked it up and worked the wheel back and forth to see if there is any slop in the u joint... None !... Also, put a big pry bar between the tire and the concrete floor and worked it to see if there was any movement in the ball joints... again. . None !... This is getting annoying! Any ideas anyone?

 

[PBJ2500CTD]

Did the springs fit tightly in the dimples on the caliper on the outer pads and did the spring fit tightly in the piston for the inner pads? The piston spring is wimpy and can bend easily during installation. Did you use any pad anti-squeal/rattle goop between the pads and caliper/piston?

 

[SKuyper]

Did the springs fit tightly in the dimples on the caliper on the outer pads and did the spring fit tightly in the piston for the inner pads? The piston spring is wimpy and can bend easily during installation. Did you use any pad anti-squeal/rattle goop between the pads and caliper/piston?

Yep ! when I pulled it apart tonight to put the hardware kit in, I checked the spring / dimple on the outer pad and bent the spring on the piston pad out, for more tension and gooped the back side of the pads when I put em back together and actually used the correct synthetic silicone grease on the slide pins/tubes. After doing all that. . test drove the truck down our road... I love wasting my time pulling the caliper down. . it rattled like I'd never touched it.

 

[PBJ2500CTD]

well nuggets...

How about the rotors? Any pulsing during braking? These pads aren't like Chinese puzzles - no fancy twisting to seat them in grooves, etc. Did the pads feel like they fit tightly when in position or were they looser than the originals? Maybe try another brand of pads if nothing else works. (I know... bad thought) I guess if the springs held them firmly in place they shouldn't rattle. Hmmm...

 

[SKuyper]

No brake pulsing, rotors are good. . pads have been on there about 4 months, are in near new condition... you'd think if something was wrong with the pads, they would have rattled from the beginning. . this just started about a month or so ago... drivers side makes no noise at all... just the pass. side... just weird !... I may just spring for some new ones of another brand just to see... these were CarQuest's best premium semi metallic.

 

[PBJ2500CTD]

I would not expect a loose brake line to cause the rattle. Not much that moves around in that area but rotor, caliper, skunks, 'possums, and pads. Beyond wierd...

 

[B.G. Smith]

Check the shock mounts on that side and the linkage on the sway bar. bg

 

[ttbird]

How about the wear indicator on the pad itself. Most are held on with a rivet, may have worked loose. If loose, just take a punch to the rivet and peen it tight. Just a thought since you've gone thru most everything else.

 

[SKuyper]

I looked at the shock mounts and tried to get movement out of the shock... nothing... don't know what that would solve anyhow... this rattle quits if I just touch the brake pedal, no actual braking force is needed... a loose shock would keep right on making noise... sway bar connectors are tight and the rubber appears to be ok.

 

[SKuyper]

The rattle is loud enough to make you think the caliper is going to fall off, if the window is down on the passenger side, going down a moderately rough gravel road... . I almost think it's the piston side pad rattling against the caliper frame or something... even though the tension spring is tight and there is plenty of anti rattle/anti squeal "goop" between the piston and pad. Checked the pad squealers too... riveted good and solid and nearly half an inch or so clearance between squealer and rotor.

 

[odieub]

how long have you had the truck, dont the rotors go on from the back side of the unit bearing. i bought a 94 4X4 ONE TIME THAT THE LAST PERSON INSTALLED ROTORS ON IT BUT DID NOT GET THE STUDS ALL THE WAT THROUGH AND WOULD DO THIS AS THE ROTOR COULD BE WIGGLED WITHOUT THE AXLE MOVING.

 

[bromano676]

Are you absoutely certain it is not from the rear brakes.



over the summer I had a problem, grinding noise, overhauled the rear axel. fluid change, rear rotors, pads, calipers, adjusted the parking breaks. took it for a ride, same thing. found the front pass. side wheel bearing shot. jacked up the front and watched the front wheel drop.



just a thought

 

[SKuyper]

Hey guys... . I found the problem... It wasn't the caliper after all... It was the right side tie rod end... it's wore enough that going down a rough road it would make a noise, jumping up and down in it's socket that would make you swear on a stack of Bibles that it was the caliper... the reason it quit when I touched the brake pedal is it torqued the passenger wheel when the brakes applied a little bit and would pull the tie rod tight. While under it today I took my hand and banged on the bottom of the drag link, out by the tie rod end and it made that nasty noise I was hearing... jacked it up and I could move the right wheel in and out about a half inch... . strange it didnt really drive all that weird ! It's parked til I get another one... if that fell apart going down the road with a horse trailer... BIG WRECK most likely. Thanks for all the suggestions and help !!!!

 

[RLHannink]

I have the caliper rattle, was buggin me for some time, was doing the same thing: clunk clunk clunk on gravel roads, but would stop at the slightest application of brakes. Turns out the caliper is a little loose in it's "place", the pins let in move about 1/16" up and down. Hopefully new caliper pins/bushings will fix it at the next brake change, but these cheapo Autozone pads are lasting forever, so might have to do it before then. Until then, stereo up a little.

 

[SKuyper]

With a pry bar, my caliper will move up and down about 1/16th of an inch at the outboard end... with new bolts, slide tubes and bushings... . same as with the old ones... So, with that in mind. . you might check outer tie rod end... it can have vertical wear that doesn't necesarily mean it steers bad... the weight of that big drag link on the joint over time can do this. See if you can move the tie rod joint vertically up and down, may take a prybar and a block of wood. . joint should have little to no movement in any direction. The weight of a worn drag link/tie rod and steering stabilizer, coupled with the inertia created by bumps can make a rattle that acts and sounds exactly like a loose caliper... . I've been chasing this one for a long time.

 

[Mr. Ken]

I don't know much, but I had this same noise on gravel roads. It sounded like something was loose, and the noise went away when appling any brake pressure. Turned out that a slider (maybe a rubber sleeve) had slipped out of place. had a new one put back in and the noise went away. They opened up a new caliper box, used the part from that, and I was on my way. I was told it never was a safety problem, but sure is nice not to listen to the rattle. At first I was told nothing is wrong, but after looking for something that was creating the noise, the problem was found. Maybe this helps, maybe not. Ken