Brake Caliper replacement issues

So a week ago I started hearing some light grinding noises at 0-30 MPH and more recently when stopping 10-0mph. Once I'm at higher speeds it's not bad at all. I replaced the brake pads last week and noticed the sound did not die out. One thing I noticed when replacing the passenger front pads is the inner pad was very low but all other were just moderate. I first tried re-lubing the slider pins thinking they just needed some more.. but as the sound continued today I picked up a caliper replacement kit. I put everything in.. after cursing for hours to get the banjo bolt off.. and bled the system 4-5 repetitions of opening, pumping and closing the valve.

Decided to take it for a test drive with the new caliper.. and.. new sound grinding pattern every full rotation of the wheel now. After putting quite some time into the job I'm not sure what to try next. What did I do wrong to cause the grinding sound? It doesn't feel like it's pulling tremendously.. but this is very frustrating. I'm hoping to get this all done sometime tomorrow.

Let me know if you pros have any ideas!

At highway speeds lets say about 70 mph when you start to brake harder does your steering shake? If yes then rotors are warped because of someone over-torquing the lug nuts.

I never really noticed shaking at higher speeds, but I that could be the case. I started noticing it after one week of really bad stop and go traffic in a construction area.. 1 hour straight of it.. and maybe that aggravated the problem. Does that still sound like rotors?

Replaced the rotor and sound of small tick/grind every rotation still.

Any other ideas?

Are you sure its not a wheel bearing?

Not sure if it is the bearing. This new sound only introduced itself after replacing the caliper. I then thought it was a warped rotor after all and with a new rotor.. same problem. I did pull out the pads and noticed the wear pattern wasn't even, top to bottom on the pads. With a few miles the pads are starting to smooth out. Possibly a quieter grind sound.. but not for sure.

Do you guys see pads make sounds when first trying to break in, and just need miles to wear them in? Just moving without braking sounds?

If it's not that.. which I'm going to put some more miles on it.. then I'm not sure what it is. I can check the bearing, it just didn't occur to me since the sound introduced itself after the caliper was replaced. Maybe it's a bad caliper replacement.. hmmm.

what do you have hub caps or alloy wheels?

sometimes hubcaps can make strange sounds especially those chrome rings they tend to make all kind of noises. Also are the rims original or after market?

sometimes aftermarket rims can be so close to caliper that they will contact calipers on the inside and can cause all kind of noises. The best for this would be for you to raise the front end, secure the car on jack stands, and slowly rotate each front wheel while you are looking and listening for the same noises this is the bast way to find out. good luck and post back what you find....

I think I figured it out...

I woke up about 6:30AM today with an idea and told my wife .. "I'm either going crazy or I think I figured it out". LOL..

It kept going through my head what parts move with the wheel that could produce that sound. I checked most everything 2-3 times. AHA!!! The dust guard clip that is popped inside the caliper. I popped it out and noticed it was slightly different to the old one. So out of curiosity I popped the old one in and took a test drive. The sound was almost completely gone. The dust guard (if that's what it's called) was rubbing on the rotor full time which explains the grind every rotation with the embroidery of the rotor on the outside just barely enough to cause friction. I'm going to just get rid of the guard for one more test drive and if that fixes it.. that's all it is. !!! If not.. false alarm.. but the comparison of the old vs new guard was huge. I'll let you know what I come up with.

what do you have hub caps or alloy wheels?

sometimes hubcaps can make strange sounds especially those chrome rings they tend to make all kind of noises. Also are the rims original or after market?

sometimes aftermarket rims can be so close to caliper that they will contact calipers on the inside and can cause all kind of noises. The best for this would be for you to raise the front end, secure the car on jack stands, and slowly rotate each front wheel while you are looking and listening for the same noises this is the bast way to find out. good luck and post back what you find....

LOL you got this in right before I finished posting my reply lol.. great minds think alike :P Oh Alloy wheels.

Also sometimes the pads get put on wrong, wear indicator should be on the inside. If not it'll grind when off the brakes but stop when applying them. :2cents:

If the dust shield is removed, your rotors/brakes can over heat.
That piece is also an air deflector to keep them cool. :thumbsup: