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As I bought my Daihatsu Feroza (aka Daihatsu Rocky / Daihatsu Sportrak) second hand it came with the usual array of "odd" noises. After new suspension bushes/bearings etc etc I was left with two separate noises that turned out to be the same thing. Having a bit of a thing about metal on metal noises meant that I had to track them down... Tools needed: None for initial test, Jack, Axle stand ( or similar ) and Wheel Brace for visual inspection ( please don't work under a car solely supported by a jack ! )
The first problem was a distinct metallic clunk from the front end on bumps ( even small ones ) and a "tick, tick" noise at wheel speed also from the front. Suspicion centered on the front CV's ( due to the wheel speed bit ) and much time was wasted removing and checking them and diff bearings/seals/bushes etc. The culprit turned out to be the front brakes. At some time in the past, a previous owner had changed brake pads and left out all the small steel shims that go between the pad and caliper carrier and pad and caliper. This allowed the pad to move up and down on bumps ( the clunk ) and in and out with wheel rotation ( the tick, tick ). 
How to check: If the noise doesn't happen when you have the brakes on you may have found the culprits - time for a visual inspection. After a bit more research I have a possible explanation - some pads come with a thin rubberized backing ( to prevent squeal ) but this makes the pad a bit thicker. Perhaps a previous owner couldn't fit the rubberized pads and the stock shims and discarded the shims ? The factory shims proved difficult to get, so I made some from shim steel ( not even spring steel ) simply bent into a U shape to stop it falling out. Problem gone. So if you take bits out - remember to keep them as further down the track you or others may need them. For "Inspection of Brake and Disc" please refer to BR-26 in the Daihatsu Manuals. |