2004 A6 SLine with 115k miles and 15k on these brake pads/rotors. Just recently I started hearing a slight "click" when braking. It is just one click and doesn't do it every time. Seems if I brake hard, it won't do it again for a couple braking times. Anyway, I was thinking it is a pad that has come loose from the metal backing. So I removed the wheel and checked the pads and all seems ok. After doing that, the noise went away for a day but is back. So I had the brakes checked at a Firestone shop and everything checked fine.

Here is the rest of the troubleshooting.
Doesn't do it in reverse.
Doesn't do it when using the emergency brake only
Doesn't do it after a hard braking stop.
Noise seems to be centrally located and not coming from the outermost points like from the wheel areas.

So, I am thinking it is suspension related, bushings possibly. Does this sound plausible? Per some other advice, I will try torquing the front suspension bolts etc.

It could be more of a clunk. It is definitely metal on metal but doesn't seem to be a transfer of a lot of force. The car does have 115k miles, so knowing that, what front suspension parts would likely be worn to the point of needing replacing?

Thanks guys.

 

Hard to say, but if it only happens when you first apply the brakes, then I think you were on the right track and it is probably a caliper sticking. Unless the noise really bothers you, I would continue to drive it as is until it gets bad enough to become apparant.

Good luck,

Bob

 

First of all, suspension noise is impossible to trace. It can be many, many different things. With that said, I had similar issue on my previous car. It turned out to be leaky shocks. It was bottoming out but not all the times.

 

Oh, I think with those miles, it's not terribly difficult. I'd say it's a control arm ball joint gone bad (there's a bunch of arms on these things). I had a similar issue. Light braking led to shudder, got progressively worse over time, but very hard braking did not cause the same issue. I let the joint go long enough that I had to put on new brakes (warped the hell outta the rotor), but it was about time anyway. So, you're going to pull so much apart on this just to check the everything, why not just get an entire kit to replace it all, in case you are thinking you'll keep the car a while. I think they're around $500 or something depending on what you get. A single arm is around $60. If I had the money at the time I would have just done it all.

Another similar rattle is developing (I've got 124k on the 6er) :dramatic "bum bum bum" playing: Another arm on the horizon, yay!

 

Check your lug nuts. make sure they are tight.

Sounds stupid but so many times I find the little things are the cause of the problem. Might not be your problem but it only takes a minute to check.