My brakes are all new. Calipers, Rotors and Pads. I am getting this clunk/tap noise when the brake pedal is applied. I did not go to Mazda for brakes, I went to my mechanic shop. They are giving me a story saying that the aftermarket pads that are installed are a bit smaller than the caliper size creating some movement play. They say this is because aftermaket pads are made that way so they can fit in many calipers across all makes and cars. They say the only way to fix this is to buy MAzda factory parts.

Is this for real? I have never heard of that. Who doesn't buy aftermarket brake jobs?

Anyway the clunk/tap noise is there and so annoying, brakes should not sound like they are falling apart.

A Fleet mechanic where I work, told me to bring up my van and said he would listen for this clunk, and he heard it 3 times, he said "that it sounded like the brake pads are sticking to the rotor" when the clunk happens, and noticed "that the rotors are highly glazed"

Anyone help? Thanks
2000 Mazda MPV

I also noticed that Mazda has a TSB for Front Brake Clunk Noise, but not sure if my Guide Plates are faulty, just know I didn't have a clunk with the old parts and now I do with the new ones.

 

Pads being loose in there holders are usually fairly easily identified if the noise only occurs once per side when changing directions and then applying brakes. Would not normally click each time the brake is applied if only moving in a forward direction. Link below to the TSB you were referring to.

http://www.mstore2000.com/PDF_Files/04-003-06-1636.pdf

 

The fleet mechanic was able to rock my wheel back and forth and with each roll forward or backward there was a clunk each time with my van in park. He suspects that same clunk is the one that is sounding off when I am driving and applying the brake pedal. To him it sounds likea worn out CV Joint. Sometimes it hits hard and sometimes soft. Hope that is it, I will get it checked out.
Thanks BH

 

Think I would still put my money on cheap and poorly fitting brake pads. Awful coincidental that the noise began occuring only after the new pads were installed with aftermarket and the noise occurs only when the brakes are applied. CV joint noise would not be dependent upon brake application either. Would double check that the caliper bolts are all tightened correctly and while you are already there use a small screwdriver to lightly pry up and down on the brake pad to see if there is any movement. There should be very little movement of the pads. Also check and make sure that the brake pads spacer shims were even reinstalled. These are the little shims that would take up any excess clearance in pad fit. Not a great pic of them in the TSB picture but they would be the ones circled in the very center with arrow pointing at them that only says to reuse. Better pic of these shims at the bottom of post. They are #6 in diagram.
What was the price you were charged for just the brake pad parts only?

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