My Montero Sport 03 AWD/4WD makes a weird sound like "clack ... clack....clack".
I changes direction and suspention parts, even bearing of the front rigth wheel but didn't stop the sound.
Brake pads are 5,000 mi old and I resurface the disc at the same time.
Could it be a AWD/FWD problem?

 

Is the noise coming from the front of the vehicle or rear?

 

The sound is coming from the right front wheel, I believe it something rotating, check break pads, safety spring, torque the screws of the caliper everything is ok.
It sounds like is breaking apart but other than the sound it self I don't feel anything in the brake pedal (like bend disc), and it only happens when little pressure is apply to the pedal.
The mechanic change ball bearing, bushings, ball joints with no improvement at all .

 

Are you sure the bearing pre-load was set correctly? Does the sound happen when you are turning the wheel or also when going straight? Does the frequency of the "clack...clack" sound increase or decrease with vehicle speed or is it constant regardless of speed? Is it ONLY occurring under brake application or can you also hear it with no brake pressure applied?

 

Try swapping the rf tire w/ the lf and see if it makes a difference. What condition are the rotors in?

 

The sound occur in any position of the wheel turning or in straight line, and yes the frequency increase with the speed, but only when I step on the brakes.
The rotor looks ok but they have been resurface 2 times. What's the minimum thickness for the front rotor so I can go and check them up.

 

Sorry, no idea. Do the pads have a wear indicator and is it positioned correctly (facing inward at the bottom of the caliper)? Are the spring clips and pad shims in good shape?

Here's the specs from a U.S. factory shop manual.

BRAKE DISC (ROTOR) THICKNESS
Standard value: 24.0 mm (0.94 inch)
Minimum limit: 22.4 mm (0.88 inch)

Thickness variation (at least 8 positions) should not be more than 0.015 mm (0.0006 inch).

 

I looked at my front disc and they have some cracks, but I don´t think this is the cause for the weird sound, I´m almost sure it come from the safe spring.
When I pull or push them they make an identical noise, can this spring worn out?
I´m going to chance the disc for new ones and have a final check on those springs.

 

It was something related to the disc brakes, I replaced them with new ones, that weird sound is gone. Checking up the right disc rotor found out there is a small crack, so after changing bearings, direction parts and bushing I finally have a quiet car.
thanks everybody