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Fri Jul 08, 2005 8:37 am

There is a clunking noise coming from the driver side on my beetle when I brake heavy. The rear brakes have less than 100 miles on them. I Put new shoes, drums, wheel cylinders, and hardware on. I took off the drums twice now to see what the problem is and I can not find anything wrong. Both E brake clips are still in place also, so that is not the problem.
I think the noise was coming from the cv shaft so I replaced it with a new one and the noise is still there! The new cv shaft is super smooth, to smooth I think. I can move the axle back and forth a lot and when I push it back and forth it makes a clunking noise from the center of the cv joint hitting the axle stubs or hubs, I am not sure what they are called excatly. (the thing the cv joints bolts to) I am pretty sure this is the noise I am hearing, but I dont know why I only hear it when I brake and it is brand new!
The axle nuts are fine and were very tight.
What do I do?

Fri Jul 08, 2005 11:25 am

Check the shock absorbers, maybe one is bottoming out.

Jim in NC

Fri Jul 08, 2005 3:22 pm

Does the clunking sound like it is in time with the tire rotation or is it random or intermittent?

Fri Jul 08, 2005 4:02 pm

The shocks are new KYB's.

Pretty sure the sound is in time with the tire rotation.

Fri Jul 08, 2005 6:03 pm

Hi Coolj30,
Also check the inner surface of the drum where the shoes do not ride against. We had a simular problem and it turned out the E-brake lever in the drum was rubbing "off and on" inside the drum. Fixed arm pivot with warpy washer so the arm was mounted tighter and no more rattle when turning.
Eric&Barb

Fri Jul 08, 2005 6:56 pm

i had a similar problem.. except mine was that the drum had the screw in wheel studs.. well they were screwed in too far and when the drum heated up, it started whacking against the retainer clips..

Fri Jul 08, 2005 11:20 pm

Eric&Barb wrote: Hi Coolj30,
Also check the inner surface of the drum where the shoes do not ride against. We had a simular problem and it turned out the E-brake lever in the drum was rubbing "off and on" inside the drum. Fixed arm pivot with warpy washer so the arm was mounted tighter and no more rattle when turning.
Eric&Barb

The inside of the drum has no signs of anything rubbing.
I will take another look at it tomorrow afternoon and check out my E brake levers. Thanks

Fri Jul 08, 2005 11:28 pm

check the suspension bushings also. mite be the case

Sat Jul 09, 2005 11:02 pm

Haridev wrote: check the suspension bushings also. mite be the case

I now the bushings I have are the original, so yeah they probably need replaced. I already have some new ones to put in. I just have not done it yet because I was waiting until I got new wheels and smaller tires and I was going to lower the back a little. But maybe I should not wait!

I put it all back together today and it still makes the noise!

Ebrake levers were fine too.

I took off the new cv shaft inspected it and rotated it. Put it back on and it did not help.

I think the problem did get less though, it really takes some heavy pressure on the brakes now to get it to make the noise.
And I have stock lug bolts in the wheels not screw in studs so I know that is not an issue either.

I have a loud exhaust too and I can easily hear this noise over it!

Sat Jul 09, 2005 11:16 pm

[quoteI think the noise was coming from the cv shaft so I replaced it with a new one and the noise is still there! The new cv shaft is super smooth, to smooth I think. I can move the axle back and forth a lot and when I push it back and forth it makes a clunking noise from the center of the cv joint hitting the axle stubs or hubs, I am not sure what they are called excatly. (the thing the cv joints bolts to) I am pretty sure this is the noise I am hearing, but I dont know why I only hear it when I brake and it is brand new! [/quote]

I have to wonder if you have an inner bearing that is shot and the breaking is putting exrta stress on it which is when you hear it. :?

Sun Jul 10, 2005 9:07 am

Is there a way to check the bearings?

Sun Jul 10, 2005 9:14 am

Hi Coolj30,
Sure! Block front tires. Jack up rears. Release E-brake. Wiggle test for more than 1/64" (.015") at rear axle nut.
If it was bearings going bad though it should be all the time and sounds a bit like a few marbles rolling around inside an old fashioned steel coffee can.
Eric&Barb

Sun Jul 10, 2005 3:01 pm

I put the car on stands today and spun the wheels by hand and did not find anything. I then started it and power braked and it made the noise. With help from my dad under the car we found out that the noise was the brake shoes hitting the backing plates. The new drums I got have a small spiral groove in the mating surface of the drums and it must be pushing the shoes over and then they snap back. I put the old worn out drum on and went for a drive and it did not do the noise anymore. So I am going to have the drums turned out tomorrow and hopefully that will solve the problem.

Thanks for all the help!