Front outer brake pad rattling inside brake caliper - Mazda3 Forums : The #1 Mazda 3 Forum
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post #1 of 12 (permalink) Old 09-28-2016, 08:09 PM Thread Starter
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Front outer brake pad rattling inside brake caliper

So to start, already searched and nothing seemed to appear like this problem.

Front outer brake pads rattle around the caliper when going over bumps and imperfections in the road.

There were some old brakes that I replaced with the Wagners. The noise went away for a few days then came back clear as ever.

Brand new pads, all greased properly and with the anti-rattle clip installed. The ball joints, swaybar links, Engine mounts and tie rods are brand new. Wheel bearings need to be replaced on both sides. The rotors were re-machined once about a year/30k miles ago.

I cannot seem to figure this problem out, minus that my struts are bad(probably) but can't see why that would cause an issue with the outer brake pads rattling. With the wheel on an a nice bang from the sledge the rattle is there.

What is the heck do you guys think this is?

Brake pads: WAGNER ZD1044
2009 Mazda 3 S 2.3L 96K miles

Last edited by m4rx; 09-28-2016 at 08:13 PM.
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post #2 of 12 (permalink) Old 09-29-2016, 10:38 AM
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Originally Posted by m4rx View Post
.... With the wheel on an a nice bang from the sledge the rattle is there....
Did you remove the wheels to inspect the caliper assemblies?

2011 3i 2.0 A/T 93K miles (daughter's ride which I maintain)
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post #3 of 12 (permalink) Old 09-29-2016, 06:02 PM Thread Starter
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The caliper assembly looks fine. The rubber is in great shape and the grooves for the brake pad's don't have any major marks from where the pad's rattle around.

I'm wondering if maybe the rotors are warped. When they were re machined the tech said they were just barely above spec.
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post #4 of 12 (permalink) Old 09-30-2016, 01:19 PM
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... I'm wondering if maybe the rotors are warped. When they were re machined the tech said they were just barely above spec.
Could be related to that. Given the relatively low cost of new rotors, I'm surprised when someone posts that the old ones were turned. Sounds like you don't DIY this stuff? If not, unfortunately you would have another 3 figure expense if you want to try new rotors.

2011 3i 2.0 A/T 93K miles (daughter's ride which I maintain)
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post #5 of 12 (permalink) Old 09-30-2016, 02:33 PM
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Don't buy garbage brake parts

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Originally Posted by m3iguy View Post
CI'm surprised when someone posts that the old ones were turned.
I had my rotors turned. Our factory rotors are Japanese made Brembo's. (BBK's are on the Speed 3, but I ain't that lucky. ) The guy down the street turns rotors for only $10 each. I would FAR rather pay $20 to have my factory Brembo's turned and keep them, than spend $80 for some cheap crap Chinese made garbage from Vatozone on my car.

I believe in using OEM brake parts. For the money, nothing else wears as good, sounds as good, stops as good, or feels as good. Cheap Chinese garbage is just that: cheap Chinese garbage. For what I saved by turning my rotors, I was able to get the OEM pads. Not the Mazda Value Lines, but the actual OEM's, and yeah, there's a difference.

If you're just absolutely broke, the Value Lines may be okay though. But whatever you do, Just Say No to the garbage from O'Reilly's, Advance or Autozone.
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post #6 of 12 (permalink) Old 09-30-2016, 05:52 PM
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Originally Posted by theblooms View Post
I had my rotors turned. Our factory rotors are Japanese made Brembo's.
Um, no they aren't. The factory brakes are made by ATE, not Brembo. Where I live everything rusts, doesn't matter if its a cheap Autozone rotor or OEM so by the time the brakes need replacing the rotors are usually so rusty that there isn't a point to turning them, if it can even be done.
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post #7 of 12 (permalink) Old 09-30-2016, 05:57 PM
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... I would FAR rather pay $20 to have my factory Brembo's turned and keep them, than spend $80 for some cheap crap Chinese made garbage from Vatozone on my car.....
I'm assuming you're using $80 as the 'don't buy' (from anyone) price point. Perhaps your focus is on 'long life' or performance rotors, but the OP made no mention of being in those categories. I took a look at the list of 'daily driver' rotors that Rockauto is currently selling, and 13 out of 15 on their list are $80 or less. So, by your standards, almost everything that Rockauto sells as daily driver is 'cheap crap'.

I've bought rotors in this price group many times, and have never found issues with any of them. But you're entitled to your opinion just like everyone else, so I guess we'll just have to agree to disagree about that.

2011 3i 2.0 A/T 93K miles (daughter's ride which I maintain)
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post #8 of 12 (permalink) Old 09-30-2016, 09:11 PM Thread Starter
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Well I wouldn't say I'm cheap by any standard, but at the time I got the rotors turned, they still looked decent and have a bunch of life in them, no rust(yay Texas). I wouldn't say they are nice rotors by any standard, but for $20 vs 140+ I might as well have them turned. The rattling didn't start until about 6 months after they were turned, which leads me to believe it might be something else.

I'm looking at either the bearing or a combination between the bearing and the struts as they are leaking a wee bit.
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post #9 of 12 (permalink) Old 10-01-2016, 12:34 PM
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How did you determine that it was the pads rattling and not something in the suspension? It could be a swaybar link.
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post #10 of 12 (permalink) Old 10-02-2016, 12:23 PM
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I would FAR rather pay $20 to have my factory Brembo's turned and keep them, than spend $80 for some cheap crap Chinese made garbage from Vatozone on my car.
I have 2 Mazda3 cars. And I found that OEM rotors on them are crappy. Pads good, rotors - not so much. As of right now, 15K miles, I like Autozone Duralast Gold rotors. Time will show. So far - not rust. Rust was exactly the cause of OEMs going bad. It encroached on the inner sides of the rotors from the pulley well.

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