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need help S1-S2 AU brake upgrade 

 

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 Post subject: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 12:13 am 
Oompa Loompa
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Ride: eb falcon

Location: adelaide
SA, Australia

hey guys,

I have just finished a brake up grade in my girlfriends AU forte,
I had access to a AUII 75th anniversary car with twin piston front brakes,

I swapped the:
lower control arms
uprights
disks
calipers
sway bar
sway bar mounts
brake lines (rubber)


During the test drive we noticed a strong road noise sounded almost like the tyres scrubbing due to a bad alignment, it goes with the road speed and starts at about 45kph, so i took it for an alignment where he said it was only just out of alignment but when i got it back on the road the noise was still there... Im running out of ideas.. The only s1 parts in the front end are upper control arm, struts, rack, tie rod ends and k frame...

Any ideas..?

Thanks kaino...
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 9:59 am 
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Ride: ford falcon au3 xr8

Location: a shit suburb in sydney
NSW, Australia

is the noise like a rumble or vibration??
the front wheel hubs might need replacing
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 2:29 pm 
Oompa Loompa
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Location: adelaide
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thanks TROYMAN

ill check the hubs for any play

the noise is like a weerrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrRRRRRRRRRR.
Its not a rattle its not really a vibration
its a constant noise that is consistent with the road speed... like a loud humm

When i fitted the swaybar mounts there where no inner bolt holes on the chassis rails... the outside was fine ... maby this is an issue.... ?

im thinking ill put a bead of mig between the sway bar mount and the chassis on the side with no bolts..
really the only thing i can think of...?

any one done this conversion.....?
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 2:30 pm 
Oompa Loompa
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Ride: eb falcon

Location: adelaide
SA, Australia

are AUII struts any different to AU forte ?
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 2:37 pm 
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Ride: ford falcon au3 xr8

Location: a shit suburb in sydney
NSW, Australia

I would still say the hub bearing are noisy, might not be any play but I have seen them noisy, and considering its a road speed thing not much else it can be..
unless your running different warn/old front tyres then before?

as for the sway bar mount, it wont cause road noise but I would be fixing the mount asap as with cornering force the brackets will flex creak and eventually crack..
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 2:51 pm 
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NSW, Australia

kaino_wankuh_face wrote:
are AUII struts any different to AU forte ?


no, there the same..
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 2:54 pm 
Oompa Loompa
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Age: 26

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Ride: eb falcon

Location: adelaide
SA, Australia

what a ball park figure on 2 new hub bearings..
The tyres on it are 17/40/245 v tread .. they are a week old but they didnt make any noise with the old suspension setup...

ill fix the swaybar mount today.. everywhere i read about the conversion said it was straight bolt up ... no one mentioned the 4 missing bolts for the swaybar mount..? is this car a freak.???

theoretically what else could it be.. bad alignment, physical contact between tyre and suspension, a bad wheel / hub bearing.?

what about an abs sensor or is there any way a rotor / caliper could make any noise...

thanks for the help TROYMAN
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 3:03 pm 
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NSW, Australia

front hubs are normally around $70 for the pair, if the tyres were not noisy before suspension swap they shouldn't be now..

yea the holes are not on the inner rail for the sway bar brackets.. something that people neglect to mention...lol
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 3:15 pm 
Oompa Loompa
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Location: adelaide
SA, Australia

personal opinion ...will a plug weld in all four hole be sufficient for the swaybar mounts... ?
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 3:52 pm 
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NSW, Australia

my person opinion would be dtill through the outside holes through the rail with a long bit and bolt it it on.. as they do have a habit of bending uf you hit big put holes ect..
plug welds will be fine but if you ever have to replace a bracket it will obviously need to be cut off if you weld it..
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 4:00 pm 
Oompa Loompa
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Age: 26

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Ride: eb falcon

Location: adelaide
SA, Australia

so drill through chassis rail and but a bolt from one side of the rail to the other side through the factory holes..?
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 4:04 pm 
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Location: a shit suburb in sydney
NSW, Australia

yes...
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 Post subject: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 4:05 pm 
Oompa Loompa
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Age: 26

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Ride: eb falcon

Location: adelaide
SA, Australia

thanks TROYMAN...!
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 5:58 pm 
Fordmods Junkie
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 Post subject: Re: need help S1-S2 AU brake upgrade
Posted: Thu Sep 18, 2014 7:04 pm 
Oompa Loompa
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Age: 26

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Ride: eb falcon

Location: adelaide
SA, Australia

smart thinking mad man....
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