Stock brake caliper rattle
 

I have a rattling sound coming from the front when going over bumpy or uneven surfaces. It goes away with the slightest touch of the brake pedal. The pads are Ferodo DS2500, and I installed them early last year.

Upon closer inspection, it appears that the calipers have a little play - I can wiggle them with my hand and they would make a rattling sound. The pads themselves are snug on the carrier and don't have any play at all. Any idea on how to fix it? My car only has 12,000km (7,500 miles) so I don't think it is due to worn guide pins. I did not have this problem with the original pads. Help!

Did you verify the guide pins are properly torqued?

Yes, the bolts going to the guide pins are properly torqued. I spent about 2 hours today messing with the front caliper but couldn't find anything.

check the indicators/shims and the shield around the rotors, could be bent

Sounds like your missing the brake pad clips. Those hold the brake pad by the sides to the caliper.

Took a video. Any idea what the cause might be for all that play?


[ame="https://www.youtube.com/watch?v=hP8XQFvof80"]Toyota 86 caliper rattle - YouTube[/ame]

Dude looks to me like you got those brake pad clips on backwards. That metal tab should be on the rotor side.

That would have no effect on what he's seeing though...

OP, have you bled the brakes recently? are you sure the slider pin bolts are tight?

Calipers will have a tiny bit of movement if you've recently pushed the pistons all the way in to replace pads, but they shouldn't be doing it like that after driving the car. Possibly air in the system letting out hydraulic pressure?

I don't think it's backwards because other photos I've seen have it mounted the same way

http://i78.photobucket.com/albums/j1...C04974_ann.jpg

That's what I thought, that I might have to re-bleed the brakes. All four calipers have this play even after driving the car for a while, but only the fronts are making the rattling sound. The rears pads are also Ferodo DS2500. The calipers on my other car have no play at all.

The last time I had the brakes bled was two years ago when I changed the brake fluid. I had a shop do the work

Any track days or heavy brake use driving conditions on the current fluid? 2 years without a flush is a long time if it's seeing lots of track driving or hard braking (heat).

Yes, I've tracked the car a couple of times on the current fluid. However, I installed the pads last July 2014 and the fluid was less than a year old back then but I was alteady getting the rattling sound.

Dam I don't know what else. It's not the clips then maybe it's the pads themselves? Maybe they got worn out really quick?

The pads still have about 90% left in them, and even if they were worn down to the backing plate, the brakes would have adjusted. That's why we use a C-clamp to push the pistons back in when changing pads, right? I'll try bleeding the brakes since I have to change the fluid anyway.

I have exactly the same issue on my car. The rattling was present with stock pads/rotors and even after replacing them with Project mu. Replaced guide pins at dealership and no difference.

Update: Today I've compared the play on my calipers and calipers on my friend's Toyota GT86 which has no rattle issues. There was a certain play as shown on video above on both cars. Nevertheless I noticed a little difference in effort necessary for moving the caliper and noise level, calipers on my car was moving slightly more freely and the sound was louder.

Just FYI, here are the parts which I've already replaced without any positive effect.

There may be a difference - did you heat them enough on track?

No on track, but pretty hard use on country road. (Conditions where stock brakes fades after several minutes)

So guys, I have some update. There are different part numbers for caliper bodies between models "from 2012/03" and "from 2015/04". Same for the slide pins.

I'll do some further investigation.

2012 Caliper body RH: SU003-04085
2012 Caliper body LH: SU003-04086

2015 Caliper body RH: SU003-06070
2015 Caliper body LH: SU003-06071

2012 Slide pin no. 1: SU003-00626
2012 Slide pin no. 2: SU003-00574

2015 Slide pin no. 1: SU003-05830
2015 Slide pin no. 2: SU003-05829

Other components are identical. It seems Toyota migh be aware of some problem.

i almost tore half my car apart looking for this darn noise last weekend. glad im not crazy.

Okay, it seems my mechanic figured out at least temporary solution. (I'm not sure how long it gonna last, I've driven my car just around 100km).

It's very easy, just pull out your slide pins, put a lot of grease which is suitable for this use on slide pins, put them back and tighten them. Then the play in the calipers should disappear, if not, just do in once again.

Worked for me, with almost no cost!

Some video found on internet for reference: [ame]http://www.youtube.com/watch?v=8IxJFoZxKaE&sns=em[/ame]

Update: brought my car to the dealer last December 10 to have my side mirror replaced under warranty (power fold was no longer working on one side). While in the shop they also performed standard 10,000km maintenance which included cleaning of the brakes. They removed the wheels, cleaned the pads and calipers and re-greased the shims and slide pins. Lo and behold, the noise went away. A month later I had the brake fluid flushed and bled. Still no noise. But yesterday, the rattling noise came back. Cleaning and greasing the shims and pins only lasted for two months/600km.

Time for a big brake kit Rob!:D

HRTROB: Maybe you can try another kind of grease and fill it really well. I've drove my car at least 1k km (incl. really hard breaking) and still no rattling. Keep trying! :)

https://youtu.be/5yaPKmRSSKo mine is driving me crazy

I got rid of the rattle by going back to the stock pads. The stock pads have an anti-rattle spring that rests on the caliper bracket, pushing itself out against the caliper to prevent the rattles. Only problem is, the stock pads suck :bonk:

Hey Rob!

Do you still have your car? I've just realised I'm experiencing the exact same issue with my Ferodo DS Performance pads + stock calipers.

Did you find any brake pads other than the stock ones that had this rattle-eliminating spring? In other words: Is there a way to have sportier pads and no rattle?

Greetings from Poland :)

Zamor86: have you put in from stock pads those two tin inserts (anti rattle springs pointed out in post above yours) that go over "ears" of pads? IIRC Ferodo pads come without them, and obviously stock ones should be reused with them. Also have you relubed guides and those ears of pads?

I have used TRD blue pads the don't come with the Anti rattle springs and yet didn't have the rattle. The calliper piston puts a bit of pressure on the pads so that they are resting tightly against the brake disc.

Its not like it is loosely fitted.

There are metal shims (upper and lower) in the calliper carrier where the brake pads fit (tightly).
Do you still have them in place?

With the calliper out and both brake pads fitted in the calliper carrier, try to see if there is any play.

I found my Liberty Gt calipers rattled when the rubber bush on the slider pins were damaged.

For reference, part numbers of not that expensive caliper repair kits of replacement guide rubber bushings & caliper dust seals for twins stock brakes: front SU003-04523 , rear SU003-04098
replacement brake pad clips: front SU003-00577 , rear SU003-00627.
Regarding guide rubber bushings, i have to note that it's important what brake lube one uses on them. Some lube that is intented to use on eg. brake pad "ears"/shims or back of pads, sometimes might be not to be used with rubber, which with it may swell and then cause some sticking, resulting in possible extra brakpad drag due them not knocking back properly due not freely moving on guides. One should use right stuff at right place.

I would say your brakes are not rattling. What modifications have you done to the front suspension?

Yes, I did reuse the brackets! However, they were switched left with right, so these thin metal fins were actually pointing downwards instead of upwards! My mechanic fixed that + added some additional anti-rattle mats on the back of the pads. It's something that EBC uses.

And, as for now, the rattle is gone! Still he told me that it will likely come back after a few hundred miles/km as the pad will get more and more worn out. I guess it's something you have to accept if you don't use the OEM pads with that extra spring.

Oh, and yes, the guides and the pistons are all good and lubed. I've changed all the rubbers in all calipers to new ones last year. Thanks!

Hey! Yes, I've reused the brackets. The calliper has no play. And the rattle is gone for now. I'll see for how long... Thank you!