Thanks for this thread and the video!
I heard clunks last night while driving and then found this under the truck in the morning.
Found this greasy rubber part under my 4Runner (makes noise now)
Here's my writeup of what was said in the video, with respect to the sway bar R&R (please correct if I made a mistake), plus what I found in a few other videos and DIYs just now.
I had never heard of a sway bar before, but looking it up, apparently the (anti) sway bar reduces body roll on turns (forcing the inside tire down) and on uneven roads. Apparently offroaders disconnect one end and some even remove the entire sway bar, and many (apparently) don't even notice it being gone when they do remove it or when the ends are sheared off.
1.
Steering Rack and Front Sway Bar Bushing Replacement
2.
Prothane Front Sway Bar and End Link Bushing Review
I just watched this 30-minute video shown in the first of two links in my last post (where mtbtim did more than just the sway bar) and he said they had the same problem with the Prothane 18-115 kit end link bushings, which were too loose (the hole was too big).
Mtbtim said that the problem is that Toyota used different diameter sway bar end links for the various 3rd-generation models.
So, the problem is to get the right diameter - which may not be easy.
Here's my summary of the sway bar part of that video:
Suppliers:
prothane.com +1-888-776-8426
energysuspension.com +1-888-913-6374
Sway Bar & End Link Bushings
Issues:
You must first measure the end link post diameter before ordering the endlink bushings!
Summit:
Energy Suspension Sway Bar Bushings 8-5118G
Front Sway Bar Bushings - Toyota 4Runner - 181115
Front Sway Bar and End Link Bushings - Tacoma, 4Runner
Parts:
Energy Suspension frong swaybar bushing kit, 27mm, 8.5118G (black) or 8.5118R (red)
Installation instructions:
http://imagesrv.catalograck.com/imgVD/ENE/17039.pdf
Prothane Front Sway Bar & End Link Bushing Kit, 26mm Bar 18-1115 (many people find the endlink bushings too large!)
Torque:
12mm Sway bar body bushing bracket nut & bolt 19 ft-lb
14mm Stabilizer bar links top nut 14 ft-lb
19mm Steering rack bushing bracket 123 ft-lb
19mm Tie-rod nut 67 ft-lb
Procedure:
Lock steering wheel (if you plan on removing the steering rack)
Chock the wheels prior to jacking
Loosen front wheel lug nuts
Jack up and place the truck on four 6-ton 15-inch jack stands
Remove front wheels
With a 14mm socket, remove the top nut of the sway bar end link
Mark the top of the top washer (as they are unidirectional)
By hand, pull off the top washer & rubber bushing off the sway bar end link
Wear safety glasses (to prevent crud falling down into your eyes)
Spray the two sway bar body bushing bolts with PB Blaster or equivalent if they look rusted
Mark the sway bar body bushing brackets so that you don't put them on backward
With a 12mm socket, remove the 12mm nut on the top sway bar body bushing bracket bolt
With a 12mm socket, remove the 12mm nut on the bottom sway bar body bushing bracket bolt
Grease both the ID and OD of the sway bar body bushings with silicone (non petroleum!) grease to prevent squeaking
Add removable locktite (blue?) to the bolts and nuts
Caveats:
There is a 26mm and a 27mm sway bar body bushing ID; get the right one!
There are different sizes for the sway bar end link diameters also; measure first!
It's hard to get a 19 ft-lb torque wrench on the passenger side bracket
Put the wheels back on and lower the truck so that the weight of the truck is on the tires before torquing the end links.
Some tighten the sway bar end links until they just start to bulge, and then back out the nuts 1/4 turn.
Other DIYs:
How to: Replace A Sway Bar Link on 3rd Gen 4Runner - YotaTech Forums
Worst luck ever during sway bar bushing replacement
Mertztr's Front Sway Bar/End Link Bushing Replacement 3rd Gen 4Runner
J.A.'s 1999 Toyota 4Runner Highlander - Additions and Modifications
Toyota 4Runner Handling Modifications Sway Bars Energy Suspensions
HOW TO replace sway bar bushings 1996-2002 Toyota 4Runner
https://www.youtube.com/watch?v=qf-M-wMrWqk
3rd Gen Toyota 4Runner Steering Rack and Front Sway Bar Bushing Replacement tutorial
https://www.youtube.com/watch?v=YywcR0E9bM4