2006 Santa Fe Front Brake Discs

22,000 miles on the clock and its going in on 8th April for the second
set of new front discs.

Front brakes judder when braking at any speed over 20 mph.

Also there is a loud crack comes from the right drive shaft when
moving forward or back. Garage packed the shaft with grease last time
and this lasted until the weekend when I hitched the caravan on for a
wek-end away.

Any advice would be appreciated.

 

Try a different shop. If you are getting warped rotors and need the second
set of pads at 22k, you are either a NYC cabbie (or at least drive like one)
or have a problem in the system. Maybe stuck calipers or something.

How heavy is that caravan and does it have brakes of its own?

 

There's probably little that can be done about the rotors. Frictio
variance around the circumference of the rotor due to pad imprinting seem
to be the primary cause of brake vibration. After that, I'd say the secon
most frequent cause is overheating. In either case, keep taking it back t
the dealer for servicing under warranty. After the warranty is up, perhap
try some well-regarded aftermarket brake products and see how they fare.
The compositions may be different, so it's possible things will change.
Of course, that change could also be for the worse.

There's a TSB on '07 Santa Fes for installing a washer between the oute
axle joint and the bearing to rectify a snapping noise when shifted from
to D or vice versa. Not sure whether this can be done to the '06. An
it's also possible the noise is coming from a different source. It sound
like the dealer initially found the problem, so now it's time for them t
come up with a more permanent solution

 

Not its second set of pads its second pair of front discs.
Caravan is only 1640 kg fully laden which is well within the 2200kg
towing capacity of the Santa Fe.

Car coming up now for 18 months old and is only used for weekend
driving and towing the caravan never been above 80 mph

 

While well within limits, that extra weight put extra strain on the brakes
every time you stop. You are nearly doubling the total weight of the
vehicle.