I own a FG XR6, I love this car, but the rattle from the front brake calipers has been driving me fkn mad for ever, just as you said, lower speeds and small corrugations in the road, if I slightly apply the brakes the rattle disappears.
Finally I fixed it!!! No help from Ford, Just had to share this.. I joined this group just to share it..
The rattle is caused by the slide pin moving left right in its location. The rubber dust boot is supposed to provide enough outward spring force to stop this happening. It does when the pads are new but as the pads wear, the slide pins sit further out of their location to the point where the rubber boot no longer applies any outward spring force on the slide pin head, hence there is caliper movement causing the rattle.
Solution:
Go to Bunnings and buy 2 packs of Century Spring Company C-566 compression springs. The dimensions are: 9.535 OD x 19.05L x 0.813mm gauge, or 3/8 x 3/4 x 0.032” they cost $2.76 for a packet of 2. Remove 12mm bolts holding calipers to slide pins, unlip the dust boot and withdraw each slide pin, insert one of these springs in each slide pin location, push back in the slide pins refitting the rubber boot. Instantly there is a small outward force, enough to elongate the rubber boot. Compress slide pin back home into its location against the new spring tension, finger pressure is all that’s needed, re fit caliper retaining bolts, done.. There is enough depth in the slide pin location to accomodate the spring as well as the slide pin pushed all the way home so as to accomodate new pads when they are fitted.
I cannot believe how quiet my front end is now, hope this helps everyone.
Cheers Steve
