2012 Mazda3 Brake Issue

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Sep 18, 2012
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DFW
After 140,000 miles on the original pads it was finally time to replace the fronts. My choice of replacement was Bosch QuietCast Ceramic. The rotors were both within spec and there wasn't any noticeable lateral runout. So, this was just a pad replacement, like the many others I've done in my life. The job went well with no hitches. I cleaned everything, lubed the correct spots where the pad tabs contact the caliper bracket. I cleaned and lubed the slide pins and made sure the bracket bolts were tight. The new pads were already backed (shims) and came with new stainless steel retaining clips.

I now have a clunk/pop sound coming from one of the front wheels whenever I step on the brake pedal. It's annoying, for sure. A week afterwards I replaced the brake fluid. (I didn't have enough to do it when replacing the pads.) I had all four wheels off and checked and double checked the front brakes. Everything looks perfect and is functioning as it should. I just have the noise. If these pads just aren't a good fit I don't plan to screw around trying to return them to RA. I would just buy a different set. I've just never had anything like this happen before.

Has anyone experienced this specific issue and, if so, how did you resolve it? TIA
 
I also should mention that the inboard pads actually snap into the pistons with three pronged clips riveted to the pads. I keep thinking I'm missing something obvious.
 
I also have a Mazda 3 (2011) with replacement Bosch pads on front and get a predictable front end clunk when putting the car into reverse and easing up on the brake pedal.

Pads went on 3.5 years and 27,000 miles ago. Bosch "blue" BE1044, which have otherwise been worth the $16.62 paid.

Perhaps I take it apart this winter and discover a missing clip or loose caliper bolts.
 
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