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I've had a few rattles I've been Tracking down. The last two things I've found are the calipers rattling in the front. They work fine but even with the little spacer and Allen bolt securing it, the caper still rattles. 76' CJ5 .
Wow you got some good hearing. More typically I would say they are froze up and won't move as needed, Are they sloppy loose? They do want to float on the bracket.
They're not too loose, they seem to float just fine, and the pads stay nice and close to the rotor. The wheel bearing nuts were a little loose which lessened the noise after reassembly but didn't get all the noise down.
I've noticed that the top of the caliper where the floating part touches the housing is making the noise. I'm thinking maybe the wedge on the bottom with the metal strip may not be tight enough. Weird problem.
Wheel bearings are ok, they were a little loose on adjustment but much better now. I just don't like the way the inside of the caliper rattles against the outer part. Its almost as though the wedge isn't pushing up enough.
If you KNOW that it is the caliper that is rattling, it has to be either the wedge or the metal strip on top of it that has worn out. The pads themselves could be rattling if the proper steps were not followed when installing them- no metal shims / silicone applied. A warped rotor could also cause chatter.
1979 Jeep CJ5 with 304 V8, T18 Transmission, Dana 20 Transfer case with TeraLow 3:1 gears, 4.88 axle gears, Detroit Locker up front and Ox Locker in back with 1 piece axle shafts, 36" SuperSwamper SX Tires, Shackle reversal, MileMarker Hydraulic winch, MSD 6A ignition.
You mention the spacer (called a support key in this picture) but there is also a spring between the spacer and the caliper. This picture shows everything except the caliper. If you know the support spring is in there check for the anti-rattle spring. It keeps the pads from rattling.