Just replaced front pads and calipers on 2006 f250. Now there's a clicking sound from passenger side (nothing/normal for driver's side) when brakes are applied--just one click, each time the brakes are applied. Any ideas on what might be causing it?

Pretty sure it has to do with those flimsy metal clips that keep the pads from dragging on the rotors. The clips appear to be installed correctly, and the brakes work fine. I did use brake lube on the little groove in the caliper where the clips slide back and forth--maybe a clip just hanging up? Bad/poor casting in that groove, preventing a smooth slide into the rotor (I think this may be it)? Calipers are remanufactured, from one of the retail parts stores--the green one.

Also, I used Bosch replacement pads and they provide 2-3 different designs of clips in the parts bag, but none were identical to the Ford OEM clips. I'm going to remove and re-do, and I might sand down that groove in the caliper, and add some more lube--any additional ideas/experience is much appreciated.

 

Resolved--and answered my own question. Photos below explain better, but here's a summary: The OEM clips have just one 'leg.' (Photo 1). That's (apparently) because there's a little bump in the casting of the caliper (see Photo 3), which the clip needs to remain clear of, in order to move freely, with the pad, toward the rotor, when brakes are applied. When brakes are applied, clip moves in with the pad, and because there is only one leg on the clip, there's no interference with the bump in the casting, the clip moves freely--and no click sound. This is with the OEM clip.

However, the replacement clips that came with the Bosch pads have two legs, not one (see Photo 1). So when brakes are applied, the second leg gets obstructed by the bump in the casting (Photo 3)--it can't move freely with the pad and the other leg. The second leg initially gets hung up, while the first one moves with the pad. However, as the pad moves further toward the rotor, the second leg eventually gets pulled PAST the bump anyway, and that's where the click sound comes from --the second leg being pulled forcibly past the bump in the casting, and finally clicking into place. There are scratch marks on the caliper, made by the second leg, to support my theory as to what's happening here.

So, what to do? 1) Cut off the second leg of the new (replacement) clips; 2) bend the second leg out of the way, 3) use the old clips, 4) buy new truck, 5) check bank balance, 6) rule out option 4, and proceed to option 7) use old clips. My answer: 7--re-use old clips. I knocked the rust off 'em; they're still springy; no cracks. Result: problem solved. No unnerving clicking noise. Brakes work great.

One last detail, for those who may care--the little 'bump' in the casting of the caliper (the castings are stamped "Ford")--this is only on the OUTWARD facing side of the caliper. The side facing inside, toward the engine bay, does NOT have the little bump. So on the inside, I used the shiny new replacement clips, with two legs. No click. Miller time.


2 clips. On the left: Clips that came with Bosch replacement pads--note 'leg' on both right and left sides. On the right: Ford OEM--note the leg on right side only.

Here's the assembled pad with original clip. Note the 1-leg OEM clip clip does NOT cover (and thus not obstructed by) the bump in the casting, when it moves toward the rotor, whenever brakes are applied.

Close-up of the clip and the caliper. Notice the little 'bump' in the casting, and that the OEM clip has only one leg, thus no interference, and thus no 'click' when brakes applied.

 

Thanks for the follow up. I would have done the same thing.... In fact I have done the same thing. I've run into issues with aftermarket caliper springs/clips/retainers not matching the OEM's I pull off...