Brakes - Rear Brake Clunk Sound

04-019

March 23, 2004

Applies To:
2002-04 Odyssey - ALL
2003 Pilot - ALL
2004 Pilot - From VIN 2HKYF1...4H500001 thru 2HKYF1...4H541020

Clunk From the Rear Brakes

SYMPTOM

The rear brake calipers clunk when you first apply the brakes after changing the direction of the vehicle.

PROBABLE CAUSE

The outer shims on the rear brake pads do not allow the pads to slide easily when you press the brake pedal. This causes the outer pad to hit hard during a change of direction, resulting in a clunk.

CORRECTIVE ACTION

Replace the rear brake pad shims.

NOTE:
Brake pad replacement and disc resurfacing is not needed to get rid of the clunk.

PARTS INFORMATION

Rear Brake Pad Shim Set:
P/N 06435-S3V-A01, H/C 7660848

REQUIRED MATERIALS

M-77 Assembly Paste: P/N 08798-9010, H/C 4503793

WARRANTY CLAIM INFORMATION

In warranty: The normal warranty applies.

Operation Number: 411150

Flat Rate Time: 0.7 hour

Failed Part: P/N 06435-S3V-A00
H/C 6406086

Defect Code: 03001

Symptom Code: 04213

Template ID: 04-019A

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 and discard the rear brake pad shims (three per caliper). For Pilots, refer to the 2003-04 Pilot Service Manual, page 19-18. For Odysseys, refer to the 1999-04 Odyssey Service Manual, page 19-25.

NOTE:
Brake pad replacement and disc resurfacing is not needed to get rid of the clunk.





2. Apply a thin coat of M-77 assembly paste to the new brake pad shims in these areas:

^ The back of inner shim A and outer shim D.

^ Both sides of inner shim B and outer shim C.

3. Install the new brake pad shims (four per side) on each rear caliper. For Pilots, refer to the 2003-04 Pilot Service Manual, page 19-19. For Odysseys, refer to the 1999-04 Odyssey Service Manual, page 19-26.





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