2012 Mazda3 Brake Issue

DBMaster · Monday at 12:16 AM

After 140,000 miles on the original pads it was finally time to replace the fronts. My choice of replacement was Bosch QuietCast Ceramic. The rotors were both within spec and there wasn't any noticeable lateral runout. So, this was just a pad replacement, like the many others I've done in my life. The job went well with no hitches. I cleaned everything, lubed the correct spots where the pad tabs contact the caliper bracket. I cleaned and lubed the slide pins and made sure the bracket bolts were tight. The new pads were already backed (shims) and came with new stainless steel retaining clips.

I now have a clunk/pop sound coming from one of the front wheels whenever I step on the brake pedal. It's annoying, for sure. A week afterwards I replaced the brake fluid. (I didn't have enough to do it when replacing the pads.) I had all four wheels off and checked and double checked the front brakes. Everything looks perfect and is functioning as it should. I just have the noise. If these pads just aren't a good fit I don't plan to screw around trying to return them to RA. I would just buy a different set. I've just never had anything like this happen before.

Has anyone experienced this specific issue and, if so, how did you resolve it? TIA

Slick3914 · Monday at 6:36 AM

Sounds like one of the pads is slightly undersized and moving within the caliper bracket.

DBMaster · Monday at 10:38 AM

I also should mention that the inboard pads actually snap into the pistons with three pronged clips riveted to the pads. I keep thinking I'm missing something obvious.

JeffKeryk · Monday at 10:51 AM

Take it apart again. Check pad fitment and torque fasteners per spec. Good luck!

johnmyster · Tuesday at 2:09 PM

I also have a Mazda 3 (2011) with replacement Bosch pads on front and get a predictable front end clunk when putting the car into reverse and easing up on the brake pedal.

Pads went on 3.5 years and 27,000 miles ago. Bosch "blue" BE1044, which have otherwise been worth the $16.62 paid.

Perhaps I take it apart this winter and discover a missing clip or loose caliper bolts.

DBMaster · Wednesday at 12:06 PM

JeffKeryk said:
Take it apart again. Check pad fitment and torque fasteners per spec. Good

I'm thinking that the tabs on the pads fit either too loosely or too tightly in the caliper brackets. I did lightly grease those areas with the included synthetic grease. If the fit is off, though, they could still "stick." I only hear the noise when the brakes are warmed up, not for the first mile, or so, of driving. The brakes are working well so dealing with this isn't urgent, but if I get ambitious I'll either try a different brand of pad, or possibly smooth the edges of the tabs on the current pads slightly.

The Critic · Wednesday at 12:13 PM

DBMaster said:
I'm thinking that the tabs on the pads fit either too loosely or too tightly in the caliper brackets. I did lightly grease those areas with the included synthetic grease. If the fit is off, though, they could still "stick." I only hear the noise when the brakes are warmed up, not for the first mile, or so, of driving. The brakes are working well so dealing with this isn't urgent, but if I get ambitious I'll either try a different brand of pad, or possibly smooth the edges of the tabs on the current pads slightly.

Aftermarket Pads are fitting too loosely - need to buy the dealer pads. The issue seems to be more prevalent with this type of caliper since it does not use clips on the bracket.

DBMaster · Wednesday at 2:39 PM

The Critic said:
Aftermarket Pads are fitting too loosely - need to buy the dealer pads. The issue seems to be more prevalent with this type of caliper since it does not use clips on the bracket.

Thank you, sir!

Dadillac · Wednesday at 3:00 PM

About 15 years ago a former boss of mine changed brake pads on his car and had a clunk when he hit the brake pedal. i checked it out and he forgot to tighten the lug nuts on his right front wheel. Its worth a look

Don

DBMaster · Wednesday at 3:53 PM

Thanks, Don. I did check everything for tightness when I had the front wheels off again a week later to bleed the brakes. The lug nuts are all torqued correctly.

Here's something interesting. The calipers and pads on the car said, "FoMoCo." I cross referenced pads and both the 2012 Ford Focus amd 2012 Mazda3 used the same front brakes. The OEM pads from Ford are $46. The OEM pads from Mazda are $115. WTH? Both vehicles use the same aftermarket part numbers on Rock Auto, too.

TCL · Wednesday at 3:55 PM

I always buy OEM pads. They usually fit perfectly.

DBMaster · Wednesday at 4:03 PM

TCL said:
I always buy OEM pads. They usually fit perfectly.

I'm trying to decide at this point whether or not to try the OEM Ford pads for 1/3 the price.

The Critic · Wednesday at 5:41 PM

DBMaster said:
Thanks, Don. I did check everything for tightness when I had the front wheels off again a week later to bleed the brakes. The lug nuts are all torqued correctly.

Here's something interesting. The calipers and pads on the car said, "FoMoCo." I cross referenced pads and both the 2012 Ford Focus amd 2012 Mazda3 used the same front brakes. The OEM pads from Ford are $46. The OEM pads from Mazda are $115. WTH? Both vehicles use the same aftermarket part numbers on Rock Auto, too.

Friction material is different on the mazda application. The Mazda pads did say Fomoco, but used NBK material per the stamping on the backing plate.

TCL · Wednesday at 5:41 PM

DBMaster said:
I'm trying to decide at this point whether or not to try the OEM Ford pads for 1/3 the price.

Add OEM hardware to that. It might cost more, but it's correct fit for good condition, stock caliper brake parts.

DBMaster · Friday at 9:36 AM

I'm ordering the OEM pads at 4x the price. Given how long they last I guess I'm not gonna sweat the $100. The sound I hear when stepping on the brakes has already become old. I've never experienced this before and I've done a fair amount of brake jobs in my life.

vwmaniaman · Friday at 9:42 AM

Our Mazda 5 had Fomoco pads too and lasted beyond 60k but I replaced them any way with new pads. We now have 160 k on those replacements and they are only half worn.

Urshurak776 · Friday at 10:08 AM

I have a 2023 Mazda 3, only 22K on it so far, but was wondering what I would use for replacement pads when the time comes. This thread is making my eyeballs hurt. I have always preferred Bosch Quiet-Cast in my cars. Never had an issue with them. Inexpensive, quiet, long lasting and low dust. What's not to like? The 2023's don't use the same size pads as the 2012, so must have been some sort of change down the line. I still may try it, but if I get the same noises, I'm out.....

Review on Amazon for the Quiet-Cast pads that fit my 2023: (YIKES!) - Maybe I won't buy them.....

DBMaster · Friday at 11:20 AM

I've used better quality semi metallic and ceramic aftermarket pads on about a dozen vehicles in my life and have never seen anything like this. Apparently there's a reason that the Mazda pads cost multiple times the cost of even the higher cost aftermarket bits.

The aftermarket belt tensioner (Gates) that I installed in 2021 has been a disappointment as well because the belt sometimes squeals, even after replacing it twice (Gates and Bando). Perhaps it puts inadequate tension on the belt. Guess I'll eventually replace that with OEM as well.

Jetronic · Friday at 11:25 AM

DBMaster said:
Thanks, Don. I did check everything for tightness when I had the front wheels off again a week later to bleed the brakes. The lug nuts are all torqued correctly.

Here's something interesting. The calipers and pads on the car said, "FoMoCo." I cross referenced pads and both the 2012 Ford Focus amd 2012 Mazda3 used the same front brakes. The OEM pads from Ford are $46. The OEM pads from Mazda are $115. WTH? Both vehicles use the same aftermarket part numbers on Rock Auto, too.

Mazda buys the pads from ford, then marlks them up. Seen that a lot over the decades

2012 Mazda3 Brake Issue

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