Brakes - Front Brake Clunking/Clicking Noises
05-012March 25, 2005
Applies To:
2003-04 MDX - ALL
Clunking or Clicking From Front Brakes
SYMPTOM
The front calipers clunk or click when you first apply the brakes after changing the direction of the vehicle.
PROBABLE CAUSE
The clearance between the front pads and the calipers allows the pads to move slightly.
CORRECTIVE ACTION
Replace both front caliper bracket sub-assemblies.
REQUIRED MATERIALS
Dow Corning Molykote M77 Assembly Paste:
P/N 08798-9010
PARTS INFORMATION
TOOL INFORMATION
WARRANTY CLAIM INFORMATION
In warranty: The normal warranty applies.
Operation Number: 410130
Flat Rate Time: 1.0 hour
Failed Part: P/N 45237-SJK-003
Defect Code: 03001
Symptom Code: 04213
Template ID: 05-012A
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
1. Remove the front wheels.
2. Remove the brake hose mounting bolt.
3. Remove the lower flange bolt while holding the caliper pin with a wrench. Repeat the procedure to remove the upper flange bolt.
4. Remove the caliper, and use a short piece of wire to hang it from the undercarriage; this will prevent damage to the caliper or brake hose.
5. Remove the pad springs while holding the brake pads.
6. Remove the pads and shims, and keep them in the correct order for reassembly.
7. Remove the two caliper mounting bracket bolts, then remove and discard the bracket.
8. Install the new caliper mounting bracket (bracket subassembly), and torque the two 14 x 1.5 mm bolts to 137 N.m (101 lb-ft).
9. Apply a thin, even coat of Molykote M77 grease to the back of the front pads and to both sides of the pad shims. Wipe excess grease off the shims and brake pads. Contaminated brake discs or brake pads reduce stopping ability. Keep grease off of the brake discs and brake pad materials.
10. Reinstall the brake pads in their original positions; this will prevent a momentary loss of braking efficiency and a low brake pedal.
11. Install the pad springs while holding the brake pads.
12. Mount the brake caliper piston compressor on the caliper.
13. Press in the piston with the brake caliper piston compressor so the caliper will fit over the brake pads. Make sure the piston boot is in position to prevent damaging it when installing the caliper into position.
14. Remove the brake caliper piston compressor.
15. Apply Molykote M77 grease to the ends of the caliper pistons.
16. Remove the caliper from its hanger, and install it into position. Install the flange bolts, and torque them to 37 N.m (27 lb-ft) while holding the caliper pin with a wrench, being careful not to damage the pin boot.
17. Reinstall the brake hose mounting bolt. Torque the brake hose mounting bolt to 9.8 N.m (7.2 lb-ft).
18. Repeat steps 2 thru 17 on the other side.
19. Press the brake pedal several times to ensure proper brake operation and pedal height.
20. Check for leaks at hose and line joints or connections, and retighten if necessary.
21. Reinstall the front wheels.
22. Test-drive the vehicle to ensure proper brake operation and pedal height, and then check again for leaks.