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Old 05-02-2010, 10:06 AM   #1
Obsessive
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Default Rubbing/Grinding Sound After Pad/Rotor Install - 2006 WRX

Hello all.

I helped a friend put new SS lines, Hawk HPS pads, and 'OE type' rotors on his 2006 WRX along with a full Motul fluid flush.

The install went relatively well, with the 'standard' rusted brake fittings (which a little bit of heat unstuck), but after assembling the brakes and bleeding the car exhibits a grinding sound (definately rotational - hits once per revolution). This is not always audible, but will start when the brakes get warm (normal driving).

We initially thought that the small anti-rattle or locating clip (they go on one upper corner of each pad on the 4-pots) were to blame as they would not stay in position as the HPS's appeared to be slightly wider than the stock pads. Removing these had no effect. All factory lube points have grease on them, as I just came off of a 4-pot install on my 2009 and remembered all the factory listed lubrication points. We also compared the brakes to mine - they matched assembly wise. Everything is clean and tightened and quadruple checked.

I found a few threads that stated that sometimes a defective rotor can cause rubbing (too large of a rotor), but by the time we get it up on stands, it seems to cool enough that it goes away.

Ideas??
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Old 05-02-2010, 10:16 AM   #2
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Quote:
Originally Posted by Obsessive View Post
Hello all.

I helped a friend put new SS lines, Hawk HPS pads, and 'OE type' rotors on his 2006 WRX along with a full Motul fluid flush.

The install went relatively well, with the 'standard' rusted brake fittings (which a little bit of heat unstuck), but after assembling the brakes and bleeding the car exhibits a grinding sound (definately rotational - hits once per revolution). This is not always audible, but will start when the brakes get warm (normal driving).

We initially thought that the small anti-rattle or locating clip (they go on one upper corner of each pad on the 4-pots) were to blame as they would not stay in position as the HPS's appeared to be slightly wider than the stock pads. Removing these had no effect. All factory lube points have grease on them, as I just came off of a 4-pot install on my 2009 and remembered all the factory listed lubrication points. We also compared the brakes to mine - they matched assembly wise. Everything is clean and tightened and quadruple checked.

I found a few threads that stated that sometimes a defective rotor can cause rubbing (too large of a rotor), but by the time we get it up on stands, it seems to cool enough that it goes away.

Ideas??
could be a bad rotor. if you can hear which one it is coming from take the rotor somewhere that has a lathe machine and have the run it on there with a dial indicater to make sure its true.
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Old 05-02-2010, 03:04 PM   #3
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Originally Posted by dlross View Post
could be a bad rotor. if you can hear which one it is coming from take the rotor somewhere that has a lathe machine and have the run it on there with a dial indicater to make sure its true.
Ahh, good suggestion. I used to turn rotors when I worked at NAPA when I was going to college (about 15 years ago )... We put them on the lathe and checked runout with a dial indicator with a magnetic base.

Didn't even think of that for some reason....

Thanks!
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Old 05-02-2010, 05:19 PM   #4
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have the same problem, same pads and oem rotors. no fluid or lines though. broke them in the way hawk recommends, expected a little noise during break in. now it sounds like bare metal contact. and they rub all the time(swishswish).
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Old 05-02-2010, 05:33 PM   #5
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The only time I have done something similar to this is when I accidentally bent the the "depth feelers" down onto the rotor, meaning those thing rubbed and made a LOUD ANNOYING sound. Took the pads back out, and bent the "feelers" back, and Bob's your Uncle.

Good luck!

- dow
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Old 05-25-2010, 12:34 AM   #6
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Any update on the grinding noise did it go away? I'm having the same issue...
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Old 05-25-2010, 10:50 PM   #7
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Same exact setup here. Hawk hps pads, oe style rotors, motul dot 5.1 fluid. Swish swish swish. I can't figure it out. I've just learned to live with it and accepted it as part of being able to stop the car extremely fast for oe calipers
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Old 05-25-2010, 11:15 PM   #8
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make sure the pad packing plate is not too large. If it is it will rub the tophat on the rotor.

ALSO, if your grinding noise is from the rear check the dusk shields to make sure they are not hitting the rotor. the lower edge seems to get bent very easily.

After that check the protrusion of the lip for the hand brake drum. There's been a number of threads that the protrusion on many aftermarket rotors is too big and it rubs.
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Old 05-25-2010, 11:20 PM   #9
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Quote:
Originally Posted by Turn in Concepts View Post
make sure the pad packing plate is not too large. If it is it will rub the tophat on the rotor.

ALSO, if your grinding noise is from the rear check the dusk shields to make sure they are not hitting the rotor. the lower edge seems to get bent very easily.

After that check the protrusion of the lip for the hand brake drum. There's been a number of threads that the protrusion on many aftermarket rotors is too big and it rubs.
Thanks for the advice. The rubbing was from the front (drivers side) only - so the handbrake drum wasn't an issue nor is the dust shield. The 'packing plate' (do you mean backing plate??) could be an issue. We didn't see any rub marks, directly after the install - but by now he should be able to see something if it's been rubbing.

From what I understand, the noise has diminished, but is still there...
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Old 05-26-2010, 06:38 AM   #10
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Yeah mines upfront too and no score marks on anything. Phantom rub lol
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Old 05-26-2010, 01:57 PM   #11
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OP, what pad are you coming from?

Since you're going to HPS, I'm guessing you might be coming from stock; in which case, this might just be the chatter the non-OEM pads sound like. After break in and wearing the pads enough to mate with the rotors, the scrapey sound goes away.
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Old 05-26-2010, 02:28 PM   #12
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lol same exact problem i have.. autozon rotors, hawk hps.. i get swish swish swish...
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Old 05-26-2010, 02:29 PM   #13
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Make sure you didn't bend the dust shield so its rubbing on the rotor. Give it a good push around its edge away from the rotor.
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Old 05-27-2010, 10:36 PM   #14
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Quote:
Originally Posted by chimchimm5 View Post
OP, what pad are you coming from?

Since you're going to HPS, I'm guessing you might be coming from stock; in which case, this might just be the chatter the non-OEM pads sound like. After break in and wearing the pads enough to mate with the rotors, the scrapey sound goes away.
HE was coming from stock (it's a buddy's car). He did say it has diminished, so we'll see what happens as the miles get put on em'.

Thanks for the input.
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Old 05-29-2010, 03:32 AM   #15
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I have the same setup and get the noise... Did anyone find out what this was besides the shield?
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Old 05-29-2010, 10:53 AM   #16
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There is a long thread on here that I can't seem to search for now (has search been disabled?)

The park brake drum often contacts the backing plate on the bottom after it has some rust buildup.

Sometimes you only hear it on turns when there is some flexing.

That thread should be a sticky. I believe it's titled something like "solution to this common problem"

-Ken
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