Clicking noise when braking after changing front axle

Hi,

I just changed both front axles for my 95 Odyssey. Now whenever I brake, I hear the click sound and my foot can feel it at the brake right before a full stop. This also happens sometimes when I am starting up.
Any insight where to start looking?

Thank you!

you are describing classic symptoms of a cracked rotor. Not necessarily related to an axle change, but it might be an unrelated failure.

Did you properly torque the axle nut, or just drive it on with an impact wrench? Are you sure the axle splines fully seated in the hub?

Thank you for the reply!
I did torque the axle nut properly, is this enough to exclude the "splines fully seated in the hub" possibility?

In general yes. usually the splines seat completely long before the torque spec is reached, but I have had situations where it "loosened up" later. My only guess is that I didn't have the splines cleaned out properly and it torqued against some grime in the splines.

Its easy to recheck the torque on it, but you're right its a long shot.

You could be right. I just noticed a little offset between the ABS sensor and the ABS ring on the axle (compares to the other side) which indicates that the spline did not seat fully in the hub. So according to your post, this will cause the clicking noise, right?
I will try to fix it tomorrow. (Can I reuse the axle nut? Just been torqued once)

Right... the hub centers on the axle by the torque applied to the bearings. If its loose, it is able to wobble a bit on the axle shaft which can cause the clicking you're talking about.

There is no problem re-using the axle nut. Its good for a few torquings. If it has a nylon locking insert they wear out after more than a few uses, but you should be fine.

Nope, not this one. I just removed it and pushed it back in and the spline is fully in, yet I am still getting this clicking noise every now and then. I did notice that the inner boot sagged because it seems to be over-stretching in order for the spline to fully fit the hub. Could this be the reason? (especially that most of the time, the clicking noise happens when the vehicle is turning and braking the the same time in low speed).