Offside Front Drive Flange

**Paula** · 9-14-09, 5:05

Hi again,

Following on form the Front ARB thread.

See: http://www.mx6.com/forums/united-kin...not-right.html (Front Anti-Roll Bar not right??)

Graham raised BaBaKa back on the hoist last Friday September 11th 2009 and checked all the bolts and nuts around the front of the car.

Kyle(Crusemad) at Trax said " Check the Captive nuts on the Bottom Arm connecting to the Chassis " but all were tight.

Then Graham took the nearside front wheel off the car and when he checked the brake disc assembly all was quiet.

However when he removed the offside front wheel and wiggled the brake disc assembly about, this is what we found and this is where the clunk noise comes from when I turn quickly right at the exit of my drive.

Still shots

So he suspects that the Drive Flange might be worn because when he fitted the O/S/F disc assembly to the nearside, all was quiet.

However he said get a new flange or good secondhand one and while you are at it get a replacement wheel bearing and studs( in case they are stretched ).

So I contacted Mark at Probestore and he can supply the bearing plus studs but NOT the flange.

So I will my local Mazda dealer and check the price or get one secondhand.

Anyone on here got said flange?

Oh yes, Graham put the wheel back on with slightly higher wheel nut torque settings to see if this helps reduce the clunk but it hasn't, so the flange etc must be really worn and no longer true.

We are getting there bit by pit.

The story continues on BaBaKlunk

Paula

**Paula** · 9-14-09, 5:13

I have sent the thread and video to Mark at Probestore

**Paula** · 9-14-09, 5:18

This is Mark's reply just now:

Hard to be 100% but I think you are on the right lines with this.

Maybe try posting on ukpoc.co.uk the Probe is mechanically the same, and the forums are very busy with lots of tech guys.

Mark

**MX6 addict** · 9-14-09, 5:33

This is the exploded view of the front hub.

What part is causing the problem?

Mark

**Paula** · 9-14-09, 5:38

I have also e-mailed this thread to Bob Clay, the Service Manager at T.W.White & Sons in Addlestone, Surrey.

**Paula** · 9-14-09, 5:39

Hi Mark,

The offside front wheel hub assembly(2).

Cheers

Paula

Quote:

Originally Posted by MX6 addict

This is the exploded view of the front hub.

What part is causing the problem?

Mark

**Paula** · 9-14-09, 6:03

Just had a reply from Bob:

Hi

Not convinced myself about the flange being the source of your noise. Usually we would sand & polish the flange , the brake disc & most importantly the inside of the alloy wheel. We would apply a thin film of grease to all surfaces & torque the wheel up as ness. With the wheel nuts up tight & centered the flange would have to be in very poor condition to allow further movement. My money would be on all the above surfaces cruddy or I would be having a good look at the caliper carrier.

All the best

Bob

I just replied:

Hiya Bob,

Thanks for your reply.

I will show all this to Graham at the MOT Shop in Addlestone.

I will let you know later in the week what he says.

Take care

Paula

**Paula** · 9-14-09, 6:23

Hey Guys,

That is making me really start to think now.

I have always had suspicions about the this and the noise, I think, started fairly shortly after below:

But everyone I spoke to said " It can't be ".

In April 2008, I had the O/S/F caliper replaced at 104,512 miles.

The car has now done 109K.

BUT is came from a Motor Factor and was not a Mazda Original Part.

The plot thickens eh?

Paula

PS. The caliper carrier was not replaced so the replacement caliper might be moving around in the carrier

**MX6 addict** · 9-14-09, 6:41

From watching the video it look's to me like the disc is slipping on the hub studs.
I'm sure that the disc should be fixed to the hub by a some small bolts. They are not so important because when the wheel is on it holds the disc in place anyway.
Sometime when a disc is replace the garage don't bother with the fixing bolts because they are so corroded they can't go back on.

New studs through the hub would be my first port of call.

Mark

**Paula** · 9-14-09, 6:46

Oh Gee,

I can't remember if the noise was happening after Graham removed the caliper and caliper carrier assembly.

I will have to ask him later this week.

This is driving me mad Guys.

There are times when I really hate cars.

G ' rrrrrrrrrrrrrrrrrrrrrrrrrrrr

Paula

**Paula** · 9-14-09, 6:47

Hiya Mark,

That makes sense.

Is this dangerous and should the car be driven?

Paula

Quote:

Originally Posted by MX6 addict

From watching the video it look's to me like the disc is slipping on the hub studs.
I'm sure that the disc should be fixed to the hub by a some small bolts. They are not so important because when the wheel is on it holds the disc in place anyway.
Sometime when a disc is replace the garage don't bother with the fixing bolts because they are so corroded they can't go back on.

New studs through the hub would be my first port of call.

Mark

**MX6 addict** · 9-14-09, 7:01

Not dangerous because the disc is held by the wheel, just very anoying!

On my old E-spec the rear disc's were held on by the wheel, they were like that for ages.

Mark

**Paula** · 9-14-09, 7:12

Hiya Mark,

Phew, I am glad and of course you did refer to that earlier...Duh !!!

Paula is getting stressed with BaBaKa's clunk as you can see.

I should take her up the Motorway and relax again as driving makes me feel better except in heavy traffic.

That's interesting re your old car, did they clunk too?

Did you replace anything on them?

Paula

Quote:

Originally Posted by MX6 addict

Not dangerous because the disc is held by the wheel, just very anoying!

On my old E-spec the rear disc's were held on by the wheel, they were like that for ages.

Mark

**clivjoo** · 9-14-09, 7:24

hi!

well, i must have mis read your previous postss, i thought you had fixed this!!

i have to say, it does look liek the disc slipping on the bolts a bit, cant say i know what or where th flange is either?

I still have my clunk by the way...it got worse, but has kind of peaked right now, only happens when i am on constant rough road, the odd bump int he road is hardly noticable, and i still cant find what s wrong!!

i'll keep an eye on your progress, it may help me you never know!

also, that noise in the video, does it coincide with the noise you hear, i.e. very metal on metal clink?? or is the noise you hear a deeper clunk...? mines a deep clunk you see, not a ligth clink like in the video!!

**MX6 addict** · 9-14-09, 7:31

It was the rear disc on my old 6, it didn't clunk but the rears are not under the same load as the front.

Mark