Been chasing a clunk now for months, and it started over two years ago as a random clunk but is now severe.

My whole front end is pretty much brand new in the last three months-
UCAs (Nitro)
LCAs OEM
Steering Rack (OEM)
Front Shocks
A few alignments lol

Vid of clunking... Boot is all buggered up and have it mostly straightened out now.
at :57 it gets up close. My theory is that the inner piston is banging against the cylinder wall on the quick front/back and side to side bumps. Even worse when aired down. 1:33 is closer, 2:05 and 2:18 are really good too for if you look closely you can see the lower part, especially just below where the lower boot clamp is, doesn't entirely look like its angle of deflection compliments the upper tube/housing/cylinder. At 3:05 is the static side. Nothing going on there. You can see some play in the sway bushings but there's not metal on metal or clunking there. Those are in acceptable condition at this time. End sway bushings at the LCAs are new.

Found another thread with same problem repaired under warranty. Mine isn't leaking FYI Front KDSS Cylinder Leaking on 2012 GX - How Serious is it? | IH8MUD Forum I'm at 90k so out of luck there. Looking to find a used cylinder, replace, and have the dealer charge the system unless there are tools out there to DIY.

Did you ever find a confirmed diagnosis/solution to this problem? I have the same on a 2014 icon lifted 4runner. Also obviously out of warranty. Dealer won't touch it since it has aftermarket suspension.

I had a phone conversation with DrKDSS a year ago when my rear ram started seeping. At that time he told me he has taken them apart and there is no way to repair or rebuild them. I didn't ask him to elaborate and took him at his word. You may want to reach out to him if you want more clarity on his opinion. I still haven't dealt with mine yet.