This is an update to the update, aka the sequel.

Well I tightened up the sway bar end link and I still had the clunk sound, grrrrr. Anyway a friend and I spent a whole wack of time under the truck looking at everything. We eventually marked everything and looked for any sort of movement. We finally found it, it was one of the lower control arm cam adjusters. It was sliding back and forth on one side. It is tightened up now and so far so good. Hopefully there is no follow up to this. I am not sure how it came loose but it had.

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Update: I believe I have found the clunk. The sway bar end link onto the LCA is the culprit. When I push hard enough on it I can move it. The nut is seized on so I have it soaking right now. If I can not get it to move and tighten it I will cut it off and replace it.

I checked the diff mounts while I was at it and they seem to be fine.


Thanks everyone for your help


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I am needing some help in diagnosing a clunk on the front of my truck. I am thinking possibly front upper control but not sure.

It is a 2002 4Runner SR5 with approximately 430,000 kms on it, stock.
Over the past couple of years I have pretty much replaced the whole front suspension. The only thing that I have not done yet is the upper control arm bushings and ball joints, everything below has been replaced. The steering rack and tie rods are new also. Motor and transmission mount were changed also. (will be checking diff mounts as suggested below)

The Problem: On the front driver’s side, I have a “solid” "clunk" sound coming from suspension area. It started several months ago but would only did it once in a while and I could not determine what was causing it. Since then it has slowly been happening more however I still can not figure out what it is.

The clunk sound is a solid sound, nothing wimpy about it and it is just one clunk each time, not a repetitive clunk.

I am not able to reproduce this when I want, it does it when it wants to.

The clunk primarily happens while under breaking coming to a stop at a light or stop sign. It has done it a couple of times after being parked. I park on a slight hill (nose down) and when I release the break and start going forward it has clunked occasionally. I have rocked the vehicle back and forth both while parked and also when driving down the road, nothing. No sounds when going over a speed bump either. It drives fine otherwise. It only seems to be happening under breaking when coming to a stop light or sign. That sort of lunging movement.

I have lifted the front and pushed and pulled at things but and all seems to be secure.

Could this be the upper control arm doing this? Sliding back and forth?

FYI, I have done all my own work

Any help or suggestions is greatly appreciated.

Thanks

I could be way off, but have you greased all the zerk fittings along the driveshaft? I know you said it sounds like it’s coming from drivers side (as opposed to the center), but that’s what came to my mind first.. I’ve read that dry or dirty/under-lubed joints can “clunk” once upon stopping or starting movements.

If it was suspension, I’d think you’d be able to reproduce the issue over bumps, etc?

I did not think of that however I will check them out. Thanks

Have you inspected your motor mounts and trans mount? Have you inspected your front differential mounts?

Motor and trans mount were changed.

I will inspect the diff mounts, thanks

I would make sure the sway bar and link are properly torqued.

Upper control arms would have to be totally shot to be clunking.


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^^^^ THIS ^^^^

Don't over think it. This comes up all the time. Loosen and re-tighten your front sway bar end links. I gave myself a nice case of 'The Sky is Falling Front End Clunks' while 'upgrading' mine.

Edit - I didn't know the lower bolts have a countersunk Allen head in the ends. I mention this just in case you haven't explored them. You'll want to use it to keep it stable while you back out the nuts. I ended up sawing my stock links off not knowing that...

If you haven't done it yet, do you ball joints. I've did mine and I'm hearing a clunk when I drive. I bet once you change them out I'm sure it'll stop. I need to redo mine and hope it'll stop as well. Good luck

My mystery clunk was the rubber sway bar-to-frame bushings had hardened and shrunk, allowing an occasional clunk. If you replace them check the bar diameter before ordering, apparently there are a couple of sizes.

Agreed, my front end clunk recently was the 3 yr old poly Prothane sway bar to frame bushing, 1mm play when pryed on. In the past it was loose end links.

Update: I believe I have found the clunk. The sway bar end link onto the LCA is the culprit. When I push hard enough on it I can move it. The nut is seized on so I have it soaking right now. If I can not get it to move and tighten it I will cut it off and replace it.

I checked the diff mounts while I was at it and they seem to be fine.


Thanks everyone for your help

Under very rocky offroading I have the same issue. The swaybar nut on the control arm will come very slightly loose and will make a clang noise when going over rocks. Super annoying but easy fix.

Have the same clunk but ignore it (not smart to do). My sway bar bushings are shot so its nice to know where the clunk is coming from.

Sometime between late 2016 and summer 2018, the drivers side front sway bar end link broke on my '97. I never noticed until I was rotating tires. I just took the remainder of the endlink off and that is how it is to this day. Be aware that no front sway bar will result in an oversteer tendency in 2wd. Not so much in 4wd.

I know your pain....