SOLVED - Front Brake “Clunk” Sound

First off, this post is not to look for answers or suggestions, but to share my opinion on what I noticed in the front brake pads and calipers and to tell you how I solved the notorious “Clunk” sound on my truck when braking.

My front brakes have been clunking since around 60k miles. It clunks when changing directions and then upon the first brake. After the first brake in that direction, it does not do it anymore. I changed my pads and rotors are 95k miles and thought that would fix it, but it didn’t. I read on another post that changing the pins and adding a second tension spring to the pads worked for someone else, but it didn’t solve the problem. I was frustrated and read that it’s normal, but it drives me crazy. I had to change the front brakes on my wife’s Subaru recently and in the pad kit they gave grease. They instructions were to apply grease on the ends on each pad steal backing edge.

I recently did my 120k maintenance and decided to look into that. What I noticed was that there is some much space in the slot for the pin on the brake pad that the pads don’t hit the pin, but rather the edges of the pad are hitting the brake caliper.

Upon pulling the pads and inspecting the ends I saw presence of metal on metal wear.
I applied grease to the ends of each pad.

I put the pads back in, wiped up any excess grease so it would get on the rotor or pads and buttoned everything back up. I took it for a test drive on my street by doing countless directional changes with braking and no CLUNK!!!

This proved that the pads are not hitting the pin, but are contacting the caliper itself!

 

Thats the way it was meant to be designed. When braking, you cant have the weight of the vehicle stopping against those pins. They are technically called pad retainers and they're just meant to hold the pad in place in the caliper. The pads are supposed to abut the heavy caliper bracket on purpose, its got the big fat bolts and the girth to slow the vehicle down

Not trying to ruin your fun, but the grease will dry up and the pads will start clicking again lol

 

wait a second. why do you have 2 of the spring clips? there should only be one on the bottom of the caliper.. at least thats how toyota does it from the factory.

 

@Empty_Lord, I put a second based on someone’s recommendation in another post. I see no issues having a second.

 

might be the source of your click, the bottom one should suffice. your hearing the pads shift.

 

Then I’ll apply more when that happens. It didn’t start this clicking until around 60k. So if it lasts that long then no problem. Otherwise if it’s shorter, I will just grease them during tire rotations.

 

The clearance between the ends of the pad and the caliper gets a little bigger from slamming around in there. I understand if you just dont like hearing the noise, just remember its not a problem and the brakes are fine

 

this clunk has been bothering me and already have the 2nd spring. need to replace the brake pads and rotors, so gonna give this a go and hope it solves it. thanks for the write-up!

 

Thanks for the heads up @TacosNBurritos

I can’t tell you how envious I am of your rust-free calipers, pads, pins and springs

 

Sweet thanks for the write up

 

@TacosNBurritos EXCELLENT Post !!!

 

Seriously.

 

Wow, those rotors and calipers look new! My truck usually sits for a week between use and after 11 years the rust was actually taking over the rotor's braking surface and eating up the pads. I cleaned them up, and soaked in evaoprust for a few days, but this is what they looked like before and after

 

Thank you. I just changed my pads and had rotors turned. After a first hard brake I hear a clunk, it only happens once. I'll try this. 2016 tacoma off road

 

So how's it holding up after a few years and presumably a few thousand miles? This is absolutely driving me crazy and I have been searching for a 10 mm socket rolling around in the skid plate

 

When the pins get rusty where the pad is retained, they will clunk a bit on first stop of morning

My new pads were too tight, I had to grind the side a bit to get them in or they would bind in the caliper

 

Very common with toyota. The asian manufacturers tend to leave some slop where the brake pads fit in the caliper...the domestics tend to make them very snug. Snug will be stuck with any rust...sloppy will be just fine.

Usually the complaints come right after a brake job...when everything is nice and clean and all the cushioning brake dust built up everywhere is no longer softening the pad shifting in the caliper. Grease does the same thing, it'll work for a bit, but not long. Mostly just ends up making a mess.

It's a characteristic...

 

For some reason I didn’t look this up before I went to the dealer, probably because I thought it was something more serious . I’ve been hearing that clank for the last 2 mos .. Dealer test drove then put it up on lift & said everything was tight and secure and it’s ‘operating normally’ . They didn’t grease because ‘the clank will just come back when the grease wears ..’

I’m ok with that and just wanted to get out of there …
Just hit 19K and I’m under warranty still so diag was no charge . I’ll grease it myself next time I rotate my tires.

 

you should only have one bottom spring retainer if you are going for oem standard.

 

I replaced the rotors,pads and associated hardware almost 4 years ago. I also added a second spring. Since then there hasn't been one clap or clunk from the pads. I don't why, I just know it worked for me.