2002 Accord Brake Issue.

Had our '02 Accord EX 4D/4Cyl in for it's 48,000km "Type 4" service. Here
in the Frozen Northâ„¢, that means:
* Replace engine oil and filter.
* Service front and rear brakes.
* Rotate tires**, inspect for wear and adjust pressure.
* Lubricate all hinges, locks, and latches with multipurpose grease.
* Inspect tie rod ends, steering gear box and boots.
* Inspect suspension components.
* Inspect driveshaft boots.
* Inspect parking brake adjustments.
* Inspect brake hoses and lines (including ABS).
* Check all fluid levels, condition of fluids, and check for leaks.
* Inspect cooling system hoses and connections.
* Inspect exhaust system.
* Inspect fuel lines and connections.
* Check all lights.
* Inspect the underbody.
* Inspect and adjust drive belts.
* Replace dust and pollen filter (if applicable).
* Replace air cleaner element.

Basically a whole lot of bullshit "inspect" line items. I'm told by the
service adviser that they took the brakes apart (nb:disks F and R) and
serviced them - and that they were fine.

I assumed that they put them back together again, but now I get a *loud*
"clunk clunk clunk, clunk clunk, clunk... clun" from the rears when coming
to a stop under very light pedal pressure. Increase the pressure to
moderate and the noise goes away. It's definitely speed dependant as it
only happens when coming to a stop (maybe in the last 15km/h->0) and gets
slower as the speed decreases. We took the car back the next day, but the
service adviser and the tech could not replicate the behaviour. Big
surprise. That was two weeks ago and it's to the point where I can make it
happen on demand - one or two stops to warm up the brakes and voila - I can
get the horrendous metallic clunking on every subsequent stop.

I've seen the Odessy, Element and Pilot TSB: 04-019, but that's not like
what I've got...

Any thoughts before I go back in and take the tech for a spin?

a

 

A (very) astute sibling has indicated that this may be a loose lug-nut or
two... makes me mad as Hell...

a

 

No one wants to guess what it was?

a

 

Why don't you just tell us and save us the time of guessing since you
obvoiusly fixed the problem.

 

No.

Nobody gives a shit.

Now bugger off, boy.

 

Hey - Dan! Did you get the anal chafing fixed? How's your lover? That's
so sad, what happened to you two...

:0(

a

 

Ok - it was a set of warped rear rotors. After the 48k servicing, the
callipers could travel way more freely and accentuated the warping under
very light brake pressure.

The dealer gave me a half off on the cost of new callipers and cut the
labour in half, too - because they just had it in (for the 48k) and didn't
catch the rotors then.

a

 

You're not being quite fair here. I can think of a dozen problems off the
top of my head that might cause such a sound. Trying to "guess" in this
case is a bit like trying to win a lottery.

My /best/ guess? Patchy glaze buildup on the disc surface. Yeah, it's a
wrong guess, I know. So fill us in.

 

Warped rotors won't cause any sounds. You will get very intense
vibrations from the car when you are on the highway and brake but
that's about it. What was the reason to replace the calipers? You
should have called Honda on this, calipers should not have any issues
until well over 100k miles.

 

That's a first. Rear rotors NEVER warp. Ever.

The rears /can/ glaze up, which can cause symptoms very close to those of
warped rotors. Rear rotors also rust like crazy in wet climates. That also
can cause brake noise.

Were the pistons seized in their bores? That's the only reason you'd ever
replace the rear calipers, unless the parking brake weather seal had
failed.