New expensive sounding noise

David

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Under medium/hard braking I now hear a terrible sound; metallic, but not exactly grinding. Maybe more like the sound you would get putting a few nuts and bolts in a blender--meaning its more than just two parts making the noise, I think. But its only under medium/hard breaking and I don't get the sense that my breaking force has been reduced.

I took the wheels off all 4 corners but didn't see anything obviously wrong. Pads had meat, no suspicious marks on the disks. Checked the torque on the bolts holding the calipers to the axle and steering knuckle.

Front bearings were replaced a year ago and I dont have any play in the front wheels (trying to rock the wheel with hands at 12 and 6 on the wheel). Outer CV joints were replaced last week which is about the same time I started to hear this. I had also cleaned and repacked the inner CV joints, and replaced the boots.

As an experiment, I got the car to around 20mph and starting to pull on the e-brake. I still heard the sound. I'm thinking maybe is the transfer of weight as the car slows, rather than the brakes themselves. I didnt check to see if in-gear vs coasting mattered. I should have.

Any ideas on where to look tomorrow ?
 
did you replace your parking brake shoes? Or are they adjusted correctly or broken in pieces?
 
I'm assuming that the e-brake shoes wouldn't really be doing anything under normal braking. Since using the e-brake or the disc brakes results in the sound, I was wondering about the drive shaft and the engine mounts too. Other than re-installing the guibo per Carl Nelson (it was not bolted up correctly) I haven't done anything with the drive shaft since it was modified by CoupeKing for the 5sp conversion.

If there is no sound until braking, shouldn't that mean the engine is moving and creating/aggravating a different problem ? Can I tell if the engine mounts are bad by looking at them ?
 
Bad engine mounts will look slumped... Not straight up and down but offset from wear.
 
You should definitely check your caliper bolts and pads.
 
Not sure where it may come from but it sounds like 1200 bucks plus tax.
 
Did you pull off the exhaust pipe to replace the CV joints? Maybe something loose here that swings forward upon braking (rubbing against the turning 1/2 shafts?
 
+1 driveshaft related

I had a nasty noise after a rock clipped my exhaust. Sounded like brake issue, discovered exhaust was rubbing driveshaft under cornering and braking. Maddening sound. Rehung exhaust with some local fence wire and we were on our way, brakes were fine.
 
I haven't had a chance to get back under the car but my brother was able to grab a recording. I had to go around the block and get on the brakes a few times to get this to reproduce.

 
Sounds like a dragging brake pad to me,in a metallic non-healthy way. And cyclical like on a mildly warped disc / drum. If the disc pads are good and calipers are free I'd go looking at the E brake.

Or maybe something stuck between the brake shield and disc??? I picked up tarred gravel while driving along a re-surfaced road. Lasted for days...not dissimilar sound.
 
Hej David!
Great of you (and your brother) to add this clip :-)
I guess above comments from Lotuss7 would help you.

Cheers!
Stefan
 
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