Hey all,

I finally figured out that the clunking I've been hearing is coming from some aspect of the front sway bar, since I removed the whole thing and had no noises coming from up front.

Sooo, I first replaced the end links, but still had some clunking, so then I replaced the bushings. While it's improved, I still have some clunking and I'm wondering if it's because the sway bar itself is pretty rusty, especially on the corners where it interfaces with the bushings.

Would that still cause the issues I'm hearing or is it something else I'm not thinking of? I'm thinking of heading to Yota Yard here in Denver to pick up another sway bar that's in better shape to see if that resolves it. Yeah, I could wire wheel it and paint it and blah blah blah, but if the price is right I'll just get one from the junk yard and save myself the trouble.

Do you have the sway bar relocation bracket? I saw from your sig that you're lifted and I know that can be an issue. Also maybe your bushings are not tight enough? Is everything torqued correctly? Maybe adding some grease with your fingers would help? Just some ideas

Good call! Yes, I do have the relocation bracket installed. It's possible they're not tight enough, or torqued correctly. I'll get under there to take some pictures, and then torque the four bolts that hold the brackets up. I didn't grease them when I installed them, so that's another possibility, but they're just the Moog ones so I was told they didn't need it. Probably can't hurt though.

I'm just thinking that even with all of that, if the bushings are rubbing against rusted metal instead of smooth paint it'll be another issue.

I highly doubt it would be making a "clunk" just from contacting rusted metal though. Just doesn't really seem likely. Yeah grease wont hurt, easy and cheap too. I would put money on something just being ever-so-slightly too loose. Has happened to a buddy of mine after he leveled his sierra.

So here’s how it looks. First thing I noticed is the split lock washer is just going into the bracket slot which is definitely preventing it from being able to get torqued properly. So, I’ll be grabbing a bigger washer from the store later.


Second thing I’m seeing is the gaps around the bushing and sway bar, again because the rust has taken away material thickness from the bar itself. I have to believe getting a bar without a big chunks missing might help?

Wrong sway bar bushing size, you need smaller diameter. Also I don't see any grease on them, slather them up!

Aside from that I had an issue on mine where the collars on the sway bar weren't holding it centered so I had to buy some sway bar lateral lock collars to keep the sway bar centered and not flop side to side, it would clunk each time the OEM collar slapped the side of the bushing which wasn't that loud but once it got moved far enough the sway bar was contacting my skid plate edge, that was loud!

Damn! I researched high and low and found other 04 sport owners were reporting the 29mm (or something like that) diameter, which I thought these Moog ones were.

I’m still going to pull this thing and see if I can’t find a better looking one at yota yard. Those rust spots have taken away from the diameter so I wonder if I had the 29 but the missing paint has made it more like 27mm.

Yeah I would definitely go with a regular style washer and torque it down snug. Also like Blackkout mentioned, those bushings look super sloppy and I don't think they are the right size. I would recommend sizing down the bushing and also picking up a new (or better condition) swaybar if the price isn't too bad.

We will get to the bottom of this lol

I remember reading that sway bar bushing thread and it seemed very inconsistent, best way to know is to measure with calipers. While the paint flaking off and puffing up makes it look like it's loosing considerable thickness don't worry, that paint and rust scale even wire wheeled off is nowhere near 1mm thickness. Clean the bubbled paint off and measure it with calipers, there's no need to replace the sway bar, just rattle can it or leave it rusty.

It's amazing how much noise you can get with that little bit of space. I also had noise and noticed the space from age so I sandwiched some bicycle tube in there and no more noise. I'll get the proper bushings at some point but now get to enjoy no clunks.

I ended up stopping by Yota Yard to see what they had and I got one for $35 that’s in better shape (but not perfect either). I compared the bushings on the one I picked up to the moog bushings and they look like the same diameter. When they’re on the bar it still looks like there’s a small gap but I dunno at this point.

I greased them up this time and put them on the new one. I also got bigger split lock washers and was able to torque the bushing bolts to 38 ft lbs, so maybe that’ll help. If there’s still noise then I’ll try to find the smaller size bushings.

I was looking into switching out bushings, etc, and started shopping around. There are several sizes for front and rear, which I suspect is due to the different size engines, 4WD/2WD. When I called local dealer parts dept, he checked the VIN, found the parts, but said the diameters were not listed. If they are needed at this point an installer will have to source the right size.

Just for future reference.

My V6 2004 4x4 front sway bar (no rust) is 30mm.

The largest I found was 29 mm, but that's in the ball park.

That area the bushing rubs on looks like it may remove the surface coating reducing the bar diameter.
...then rust.

pic 1 is the bar
pic 2 is reference...broken non digital...still works though.

Attached Images