D4 front rattle is loose caliper

[Graeme]

I think the rattle that occurs over bumps is the RH front brake caliper rattling, as its very loose even straight after pushing the brake pedal hard. The left one is a little loose but nothing like the other and the noise only occurs from the right. I suspect its time to investigate a loose wheel bearing!
Nothing was found to be loose at its recent service when investgating my reported noise but maybe only bolts and bushes were checked.

[Graeme]

Inspection revealed the wheel bearing is not loose. The pistons are pulling back into the caliper as soon as the pressure is released which suggests that both pistons are binding on the seals and springing back to their original position - about 1.5mm. When I have a bit more time I might try applying the brakes with only 1 pad fitted so as to force the piston to slide on the seal, although this could damage the seals causing it to leak. It seems that the caliper may have been assembled without lubricant.

[CaverD3]

So Lr are still doing that.

Early D3s had calipers assembled without lube, caused calipers to stick on.

[Graeme]

CaverD3,
Do you know what LR did about the problem, if anything?

[CaverD3]

Not sure what they did but have only heard reports on early ones, maybe they discovered it in QC and it improved. A good idea to lube the caliper slides as the amount put on at factory will vary anyway.

[Beamin]

... The pistons are pulling back into the caliper as soon as the pressure is released which suggests that both pistons are binding on the seals and springing back to their original position - about 1.5mm. When I have a bit more time I might try applying the brakes with only 1 pad fitted so as to force the piston to slide on the seal, although this could damage the seals causing it to leak. It seems that the caliper may have been assembled without lubricant.

Hi Graeme

Did you find a fix for this? I think I might have had the same problem, a light clattering sound from the front on bumpy dirt roads/corrugations that went quiet whenever the brakes were applied, but the dealer can't replicate it or find any problem. I haven't heard it for a while myself, so perhaps it has "fixed itself" (??)

[Graeme]

I haven't noticed that noise for some time so it may have fixed itself. However the general knocking that's been there since new when moving slowly over sharp ruts (especially in reverse) is more of a concern, even though I understand the noise is normal and only overcome with after-market bushes.

[Disco4SE]

I had new bushes put in mine and the noise went away.
Was told by LR that the originals are not so good. The replacements are far superior.

Cheers, Craig

[Graeme]

Ah, that's good news Craig. I'll bring the situation to the dealer's attention and hopefully will have it done at the next service.