Hopefully, not too repost(y)...

So my DIY skills are being called into question, need some insight, please.

Started a brake job on my 03' MINI S, pad sensor light had come on. Replacing worn out oem bits, i.e. pads and rotors. This isnt my first brake-rodeo, but still I have hit an issue.

Installed Brembo rotors (oem replacements, non-vented, not-drilled), and using HAWK HPS pads.

Did the front only thus far, but I am getting a pretty horrific noise from my drivers-side wheel. Its a rotational clunk/thunk that occurs when the brake pedal is pressed.

Only happens when pressing medium-hard on the brake pedal, does not happen when lightly pressing on the pedal, or when aggressively "standing" on the pedal.

There is NO pulsing of the brake pedal. Brakes stop the car as they should, slows down straight/tracks straight, and there is no rotaional noise as the wheel simply rotates down the road, only clunks/thunks when braking (med-hard).

Almost seems like a pad is too loose in the carrier, and is shifting under braking. I've had the brakes apart numerous times, trying to remedy this but to no avail.

Still have to do the rears, and have stainless-steel lines to add and then a full power bleed with super-blue, but want to figure this problem out before I get too far, help!

Any thoughts?
Much appreciated

P.S. I cut and spliced the front brake sensor wiring... turns out the sensor that had tripped first was the rear... how odd is that?

 

It does sound like you dont have the pad seated right. Did you get the anti-vibration shim in right? Just a thought.....good luck

 

you did put the caliber retaining spring back on right?

I left it off once but fortunately discovered this as I was cleaning up "after" and found it on the floor

 

Funnily enough, the first time I finished up on the front brakes, I noticed the spring sitting on the floor just after I let the jack down, lol.

But it IS in fact on there... Perhaps it has weakened?

 

is it hard to get back on? if not then maybe you bent it in a way it is not providing enuf tension.

compare to the other side...and maybe even switch them from side to side and see if the problem moves

 

Hmmmm, thats a good idea.
I'll give it the ol' switch-a-roo.

Trying to figure out all possible causes, maybe:
1) bad tension spring
2) the guide/slide pins? do they wear out?
3) poorly seated pads

Thats about all I an think of, I mean there are only sooo many brake components... arggggg, lol.

Thanks for the suggestions....