Hi all,

I recently replaced the front brake calipers, disc and pads on my 2004 Sport 4WD. The calipers are rebuilt ones from Autozone. Everything was fine for about 4 months. At that point I started noticing a "clanging" noise of sorts every time I touched the brakes pedal. After some poking around I realized it was the sound of the pad hitting the disc. About two weeks later I started hearing the same noise as the wheel rotated. It appears to be from the brake pad lifting and hitting the upper limit of the caliper, then falling as the wheel turns. The noise increases with a faster rotation of the wheel. Lastly, whoever I hit a bump, even small ones, I hear the same type of clang.

I removed the pads and measured their vertical height and compared them to another major brand. The ones from Autozone were about 20 thousandths of and in shorter. So I return them and put the new brand of pads on. Everything was great for about two months, now all of the above is repeating again.

I'm wondering if the calipers were overly worn when rebuilt and have too much okay in them, hence all the sloppiness with the pads.

Has anyone run into this problem? The noise is really loud and sounds like the truck is falling apart as I drive it. It's getting really annoying.

Sorry to hear about the problem. It's hard because I/we can't see what you see. But I can't imagine how pads would "lift". Maybe double check that the 2 caliper pins are through each caliper and the clips in place, making sure they are through both holes in the caliper and also through both brake pads?

Or, if you see something that does not look right, post a pic.

Good luck

Agree.

Sounds more like brake pad retaining hardware has either fallen off or has failed in some way.

The calipers, themselves, shouldn't make any noise.

Post a pic so we can see what you are talking about. Which caliper does your 4runner have? There were 2 sizes don't know if that is an issue in this case.

I have no idea what your problem is from that description, but if you do think the problem is the calipers, return them. Autozone has a warranty and you can swap them at any time. It is only two bolts, a hose, and a bottle of brake fluid.

Just a thought, but did you install the small metal slider clips that fit in the slots in the caliper that the upper and lower tabs on the pads fit into? These clips are 'spring' loaded to help keep the pads from moving vertically with the disk rotation, but still allow the pads to move in and out as the caliper pistons apply and relax. If they are not in place, I could see the pads making noise as they shift with the rotor movement.

Thanks for all the replies. Those are all good thoughts.

The pins that run through the caliper and pads are in place. The small clips that keeps the pads away from the disc when not engaged are also in place.

I do not recall there being any type of slider clips on the caliper itself. I will double check that.

I did triple check that the rebuilt calipers I received had the same casting number as the originals.

I will take photos the next time I have the wheels off.