09/30/2026
CUSTOMER CONCERN
Customer states the vehicle is making a loud popping noise that sounds similar to a failed ball joint or other suspension component. Customer requested inspection and diagnosis of the noise.
CAUSE
Upon inspection, we found the front brake pads were completely worn and approaching metal-to-metal contact. The front brake rotors were also heavily worn and had developed a significant lip.
After removing the driver-side wheel and continuing the inspection on the passenger side, we found one wheel stud missing. Upon removal of the passenger-side wheel, we discovered the wheel stud threads were damaged/stripped, requiring replacement of the passenger-side hub assembly.
On the driver side, we also found that one of the brake caliper mounting/slide pin bolts had broken, allowing the caliper to lift out of position and make contact with the inside of the wheel. This was determined to be the source of the popping/clunking noise reported by the customer.
CORRECTION
Replacement front brake pads and rotors were obtained through a local parts vendor, along with a replacement passenger-side hub assembly and wheel stud/lug hardware. A new brake caliper pin/bolt hardware kit was also obtained for the driver-side caliper.
The customer was advised that, due to the condition of the driver-side caliper and the broken hardware, replacement of the caliper should be considered a priority future repair. Although the caliper was secured with new hardware and was functioning properly at the time of service, its continued service life cannot be guaranteed.
All approved components were installed and secured. The braking system was inspected after installation, and the new brake pads and rotors were properly burnished/bedded. A final operational check was performed to verify proper brake operation and confirm that the repaired components were secure.
Vehicle was operating properly at the completion of service. Customer was informed of the recommended future driver-side caliper replacement.