I had a little fun with this thing yesterday-in the way that nearly losing a wheel on the interstate is fun. I'd been getting a worsening noise from my driver's side front end that I thought was the CV axle eating itself (I had the same sound from a bad passenger CV previously) so I was planning to replace it when I got home for fall break. I managed to make it half way home before I started to get some drag from that front wheel, the car would jerk almost out of the lane when I would hit the gas or let off and engine brake. Finally I pulled over at a truck stop, and noticed something was now grinding from the driver's front wheel. Got out and saw this:
Apparently I lost the cotter pin from the hub nut, and never noticed (for several weeks!) as the nut backed off and let the hub slide out.
If you look at the top corner of the caliper, you can see the little slot that the rotor had been milling away into it, as well as some discoloration from the heat being generated from metal on metal contact. Aside from this, there's no other damage. I didn't have any tools with me in this car, so I had to borrow a pair of slip joint pliers from a trucker to get the hub pressed back into place and the nut tightened. I managed to find an old quick release pin in a can of hardware from another project to get it pinned temporarily to make it the rest of the way home. As soon as I got back, I threw some blue Loctite on the nut, tightened it down and put a new cotter in it.
But that's not it.
That adventure was yesterday. Today, I went for maybe a 15 mile drive to my buddy's house, and I was telling him this story and got to looking at the hub nut, and it was loosening again! We pulled the nut, and this is all that was left of the brand new cotter:
What. The. ****.
This time we busted out the red Loctite and the torque wrench and ran it down to around 150 ft/lb. Then we dug around for a grade 8 bolt that fit the cotter hole and castle nut, and put it in along with a nyloc nut douched with Loctite for good measure.
If it fails again, I'm either going for the green Loctite, or I'm gonna stick weld the ***** together and never take it apart again.
Moral of this story is: don't ignore those noises, even if you think you know what they are; and carry tools in all of your vehicles (as soon as I got home yesterday I filled a spare box with extra tools from home and some new cheapies from Harbl Freight, along with bailing wire, zipties, electrical tape, etc).