I believe finding the culprit isn't out of reach, but as
@
clearock
mentioned, 2 people are needed. I would determine if the clunk is coming from the steering shaft or the rack. I'm not convinced the clunk noise has anything to do with the alignment concerns.
That change in toe is interesting. Not sure how long/distance between alignment with improved gas mileage was to current alignment, but a single shift in toe (the others barely changed) that significant indicates 1. previous tech didn't tighten tie-rod 2. failing component.
If you experience wonder or bump steer at all, I'd look at ball joints. My experience with newer techs has been they don't have a good understanding of differences in suspension design. These Toyotas have the lower ball joint riding in compression (inverted)... so you have to unload the joint to check for play. I should note my truck did not give the impression the entire front suspension was shot -- but it was.
I had issues with clunks and sudden steering effort increases... to the point it felt like the wheel was "stuck". It was random, happened at different degrees of turn and sometimes was gone all together! As hard as I reefed on the steering wheel when it would happen, I was certain it was a failed rack - nope, it was the CV joint on the steering shaft! Yep that mysterious part
@
sleepydad
posted 4529035040 YOKE SUB-ASSY, STEERING SLIDING (on 1st page) is a double cordon joint - different than a "rag joint." I believe it's only on the tilt columns. There was a "disk" inside the bolted together halves that was almost seized up/no lubricant. Shot some lube in there and bam - my problem 100% gone.