Strange noises are hard to diagnose online but ill give it a shot...

Been having noises from the passenger side front wheel area. When i brake at speeds around 40mph or lower i hear a 'pop' type noise. It sounds like someone tapping the spindle with a metal hammer. It happens mostly when braking at the mph mentioned but has also done it while turning to the left and braking also at low speed. Twice in the parking lot while driving slowly, no brakes, i heard the same noise but it sounded like something was dragging right along with the noise.

I took the wheel off and tried to move the rotor, caliper, tierod, and checked the strut for abnormal movement. The only thing i noticed is that the caliper has a lil bit of movement on the anchor pins. The caliper rocks a few hairs. Normal? Nothing is broken or missing. So i put the wheel back on. I also checked the wheel bearings and all was good.

With the engine running and turn the wheel side to side i hear that noise again but not as noisy as if i were driving and braking. BTW, the noise does not present itself at all while braking in reverse. Curious, ii popped the hood and grabbed the steering shaft and it has a LOT of play in it IMO and heard the same 'pop' type sound like i would as mentioned above so i thought the rack may be the source of the noise. But the sound while driving sounds like its closer to the wheel. I checked the tierods and both looks healthy. Nothing broken, bent, or missing. Dust boots intact and full of grease. Same for the balljoints.

Buddy of mine said its the balljoints. I just had them replaced but the noise was there before that so im rulling the joints out. I looked at the coil springs orientation and the end of the spring and the hole in the control arm look lined up correctly.

I cant find anything wrong but i still have this noise and id really like to figure it out. The only thing i havent checked yet is the strut itself and its mounting but i did just get an alignment and it didnt need much correction. its a good honest shop and if they find something wrong they say so, even if they broke something which has happened.

Suggestions?

Also, my drivers door lock. I put a new motor put in last year. Worked great. A few months ago ive been having trouble using the key and the lock button when its really cold outside. The key doesnt work if i lock it and i cant lock it using the key either. Sometimes the power button wont even work the motor or itll work halfway. Ive been lubing the workings for the lock but it hasnt been helping. Could the cold be freezing my lock motor? Its the only door ive replaced the motor on so if thats the problem can removing the motor altogether solve this problem? BTW, its not a Ford lock motor. Im thinking about ditching power locks anyway but id still like to solve this problem.

 

Sound frustrating. It sounds like you have checked just about everything. Have you had a buddy listen from the outside when you turn the wheel to see if they can pinpoint where the sound id coming from? That might help you locate the problem or atleast narrow it down a bit.

 

Its still driving me crazy.

I still have the noise but i think i narrowed it down with a little help from my mother. We pulled the passenger side wheel and noticed the caliper is a tad loose but not sure where. Niether of us could wiggle the rotor so we ruled out the wheel bearings being bad or out of adjustment. Could it be bad guide sleeves in the caliper? Theyre still the stock rubber pieces which im looking to replace with new ones.

The rotors are Power Slots and have a slight groove in them near the center of the hub all the way around it, and the outer pad has a raised ridge that coincides with the groove on the rotor. Is that some form of wear indicator built into the rotor?
Im replacing the rotors anyway but if anybody knows of what else i should look into if that doesnt fix the noise and loose caliper. I should note that i put new caliper grease on the back of the pads and the two fingers over the caliper and the noise seems to have gotten worse and can feel it and hear it from time to time on the freeway. Ill apply the brakes and the noise stops for a while. When turning in the parking lot, going right, ill still hear a pop every so often, at a slow speed.

Who sells a good guide sleeve? Do you think thats even part of the problem? Should i get new bolts? They look fine. The caliper is bolted tight. Everything but the rotors and pads are original pieces. All 4 pads still have a good 1/2" on them. Can i still use the pads after grinding the ridge down, or am i better off replacing the pads? Id hate to toss a pad with 1/2" still left on it but i will if i have to.

The drivers side rotor has a slight groove in the same place but theres no noise and wiggle at all with the caliper.

Also, i think my steering rack is a bit worn. I turn the wheel quick back and forth and can hear it clunk. Had my mother turn the wheel while i checked under the hood and the shaft had maybe 1" worth maybe a tad more of rotation before it worked the rack. Theres more play one way than the other. When im in the car, it sounds like its coming from the passenger side. My mother couldnt really hear it outside of the car and i couldnt either. Rag joint is still nice and solid. I checked the rack mounts and theyre solid to. Its a power rack if that means anything and the fluid is still good and full. Tie rod ends are nice and tight.

This is all for a 93 GT with about 144,000 miles.

 

Crazy questions, did that year have front wheel bearings attached to the lugnuts. Mine was making the same noises(later model though) and replaced the whell bearing(all one peice) and the noise is gone.

 

Wheel bearings are seperate from the rotors. I think that changed starting in 94.