Ford Maverick Front End Banging/Rattle noise over rough pavement

[austenite]

Hey All,

I bought a used 2022 Ford Maverick XLT FX4, with the 2.0L engine. 33000 km. I changed the front brakes, all new Raybestos Element 3 rotors and pads, with new sliders and rubber bushing boots. The OEM rotors were in poor shape.

I noticed that after I reassembled the caliper and slider pins, that the caliper was unusually loose. I could move it quite a bit by hand....of course, I had not seated the piston on the pads yet, but it was far more than the dozen other car models i have done brake jobs on. The pads fitted easily in the caliper bracket. After I seated the piston, the caliper seemed firmly in place over the rotor.

Driving around, I have noticed some severe rattling/banging/clanging noise from the front end only when I drive over very rough pavement. Braking performance is great. I suspect the pads or caliper may be jiggling like chicklets when traversing rough pavement.

I was wondering if anyone else has experienced this...is it normal? is it from using after market brake parts? Is it normal just for the FX4's?

It feels really junky over rough terrain....and making me second guess my choice.

I have checked all the suspension components and everything "looks" fine. It's also my first pickup style vehicle...as I drove a Ford Escape before.

Sponsored

 

[AutobahnSHO]

Should NOT be making noise.

We had a small rattle within 6months of buying our 2023. Dealer put some mics under and went for test drive, replaced defective strut under warranty.

 

[Scottybox]

Something simple to check, is you hood prop locked in place?

 

[austenite]

Something simple to check, is you hood prop locked in place?

Confirmed....hood prop locked in place.

 

[austenite]

Should NOT be making noise.

We had a small rattle within 6months of buying our 2023. Dealer put some mics under and went for test drive, replaced defective strut under warranty.

I will rig up a camera and mic near the brake caliper and see if I can confirm its coming from the caliper assembly. Unless there is something internal going on with the struts....I will have to eliminate each suspect component. I actually brought it to the dealer for this problem and they couldn't figure it out. They just smeared tonnes of grease onto the outside of the pads and logged it as solved.

 

[Master Blaster]

Did you damage or forget to put in the anti-rattle spring shims?

 

[austenite]

Did you damage or forget to put in the anti-rattle spring shims?

The shims are installed. The brake job is perfect. I've done brakes on a dozen car models for 25 years with no issues.

I am wondering if its a tolerance issue with the pad fit?

Maybe when more 2022's have their first brake jobs this might register as a common issue?

 

[ScottyC]

Usually, Raybestos is a top notch replacement item for brakes....must be something in conjunction with the brake job...I would double-check the bolts and check the backing plates / spash guards.....also, check to see if the other connecting points in the front suspension are good.

 

[austenite]

I did another inspection of the front brakes. There seems to be a lot of play in the slider pin to bracket interface...more than other vehicles I've had in the past. I measured the diameter of the Carlson brand sliders...and they measure 11.96mm diameter. I checked the old sliders that I saved, and they are 12.03mm. I didn't replace the slider boots during the brake job....I thought they were supposed to come with the Carlson slider pin kit...but they didn't.

I ended up replacing the slider pins with the old ones after I took this video....which made a minor difference while driving.

Will buy some OEM pins and boots at the dealer and hope that fixes the problem.

The rattling is pretty insane on rough roads.

I attached a video to show the noise of applying hand pressure to the caliper and pads.

 

[vertigo12369]

This is interesting. I have a similar issue post brake job. I reused the OEM slider pins. Seems to be loudest from front left. Will replace pins and see what happens. Any update from your side?

 

[Escapologist]

I stopped going to chain tire and brake places, 'coz the 2nd or 3rd time you brought it back for rattles, it'd get mummified in the "red goop" sometimes more orange. Anyway, "disc brake quiet" is the official name of the crap.

 

[austenite]

This is interesting. I have a similar issue post brake job. I reused the OEM slider pins. Seems to be loudest from front left. Will replace pins and see what happens. Any update from your side?

I ended up buying OEM slider pins and boot/bushings from the dealer...and replaced them. That improved the calipers stiffness quite a bit. As a result the rattling noise has mostly disappeared, however, on the roughest roads there is still a bit of rattling. Maybe I am hyper aware of the noise, which would otherwise be normal for other people.

I also made a warranty claim with Raybestos, because the pads looked like they were cracking and disintegrating. The company was quick to send a new set. The pads did seem to fit more firmly within the brackets. I think Raybestos is not what it used to be. I wonder if their India production has introduced product quality issues.

 

[twracing]

Something simple to check, is you hood prop locked in place?

So I’ve a clunk coming from the left front for a couple of weeks. Found this thread. Sure enough, my hood prop was not locked in. Problem soved. Thanks for chiming in.

Sponsored