NOISES FROM FRONT END

[chrislb]

I finally fixed a frustrating issue with my 2003 Corolla Sportivo.

After looking at all the suspension components including the replacing of lower control arm, sway-bar, and S/B link bushings and checking nuts and bolts for tightness and rebuilding the struts I was able to trouble shoot a ongoing noise issue I could not resolve.

When going over cement or choppy road surfaces there would be a noise from the right front of the car. Something loose, for a while I convinced myself it was the tyres making the sound.

The car had no steering vibration or brake vibration. On asphalt no noise! One day going over the same cement road I needed to apply brakes and the noise DISAPPEARED!

I did some more testing by left foot braking while using the accelerator, indeed the noise stopped and returned after lifting off the brakes, so I narrowed it down to the braking system.

One YouTube video showed how the disc can make a noise when the studs bang against the holes in the rotor hub. But that could not be the cause. Rattles can come from brake pads, so I cleaned and re-greased the backs of the pads in case it was that. I also shook the whole assembly when it was all back together.

Nothing a first but then suddenly I heard the EXACT SAME NOISE that had been plaguing me for months.

Turns out the 17mm bolts that hold the brake caliper assembly to the bracket had worked themselves loose. (Just enough not dangerous)

I lock tighted them back in place and no more noise, hard to diagnose for a non mechanic so it may be useful information for other DIYers, could save you hours of frustration.

I think giving stuff on your car a good shake is a great old school way to pick up issues early

Hope this helps others👌

[Tony Prodigy]

I've never heard of brake caliper bracket bolts coming loose ever.

It's possible those 17mm bracket bolts weren't tightened to spec which is around 80 lb.ft. The loctite helps but it's always good to use a torque wrench for such items so over tightening doesn't occur or stretching of the thread. 

Maybe it's a good idea to get some new bolts from Toyota and swap them out, then torque them up. 

[chrislb]

Yes an unusual situation. I torqued the bolts to spec, it was probably my fault, I refurbished the brakes about 2 years ago. The drivers side calipers, it's not easy getting a torque wrench in there to fit, I may have only hand tightened the bolts with a spanner. The car now is so quiet amazing its got all new whiteline suspension bushings and new springs and struts, drives like new car with a great engine (2zz - ge) How I thought there was nothing wrong is amazing to me now.

The difference between a mechanic with experience working on many different cars and situations, and a DIYer who lives in a bubble of the car or cars they own. I'm sure an experienced mechanic would have recognised there was a problem straight away.

[Tony Prodigy]

46 minutes ago, chrislb said:

Yes an unusual situation. I torqued the bolts to spec, it was probably my fault, I refurbished the brakes about 2 years ago. The drivers side calipers, it's not easy getting a torque wrench in there to fit, I may have only hand tightened the bolts with a spanner. The car now is so quiet amazing its got all new whiteline suspension bushings and new springs and struts, drives like new car with a great engine (2zz - ge) How I thought there was nothing wrong is amazing to me now.

I'm glad you're happy with it Chris. There's nothing more satisfying knowing everything is solid and in good working order. 

 

46 minutes ago, chrislb said:

The difference between a mechanic with experience working on many different cars and situations, and a DIYer who lives in a bubble of the car or cars they own. I'm sure an experienced mechanic would have recognised there was a problem straight away.

Don't be too hard on yourself. We learn through trial and error. Best way sometimes and the lessons we learn end up saving us a lot of money.

Take care 

[chrislb]

CHEERS THANKS FOR YOUR COMMENTS😀