94 4.0, AX15.

So...everything in my front end was replaced. I had all new suspension...everything fine.

I put on new rotors, new calipers, new pads, new unit bearings, new U-joints, new shocks, new springs....LITERALLY the front end is new.

I started to get a clanking in the front driver's side. Sounds like it is coming from the brakes. So I got some anti-rattle clips.

Put on the anti rattle clips today. Sound is still there....but now the clips rub on the rotors...

The sound is most pronounced between 25 and 30 miles per hour.

I am convinced it is coming from the brakes somehow.

Sounds familiar to anyone? Anyone have any insight? It's bugging the crap outta me!

Thanks guys!

 

well, first the little backing shims should in no way be touching your brake rotors. I would investigate that. Use some silicone on the backs of the discs (auto supply) I've never heard of brake noises described as 'clunking' but I guess if say, your calipers were loose they might clunk a bit. I would suspect another area with all the recent work you've done. good luck!

 

It's not the backing shims touching...its the anti rattle clips.

I am thinking also, since the top front corners of the pads have experienced wear from this...flipping the pads to the opposite sides.

 

Those anti rattle clips are garbage. Mine were rubbing the rotors when I bought my Jeep. I even bought new ones thinking the old ones were bent. The new ones rubbed the rotors just the same. I took them off 5 years and 80K miles ago and my brakes have always worked fine...and quiet!!

 

I only tried them because of the rattling....I will be removing them.

 

Does it do the clunking noise in reverse too? Is it only when speeding up, slowing down, cornering or all the time?

 

It does it most when just cruising at neighborhood speeds. It diminishes when I hit the brakes...but is still there.

I do not know about reverse. Haven't been able to get up to cruising speed...lol

It's also more of a clanking...rattle...rotational sound.

 

Something on your hubs or rotors is hitting your splash covers. If anything even barely touches those things it makes the most gawd awful noise because they are just thin sheet metal. Just like hitting a symbol.

 

Removed the splash covers long ago.

They were just mud and rock holders when offroading IMHO.

 

I would have to agree with you about the splash guards. Good choice. Okay next thing would have to be U-joints. You said you replaced both of them. Did you use the press, vice or BFH method to install your knuckle U-joints?

 

Always a press....always delicately.

The sound was there before and after u-joints.

I am suspecting the anchor slides on the knuckles.

 

Maybe over torqued your lug nuts and warped the rotor on that side?

 

I don't think so. I have a harbor freight electric impact I use. If it over torqued them I would be surprised...lol...I hand check them after.

 

Could have possibly over tightened your caliper bolts and stripped the threads on one of them.

 

No...they are still good to go.