Clunking noise in front suspension- Really annoying!!!

[Frenchie]

Hi,

I did a search everywhere on here and on Google and I can't find anything that can help.
My 03 TR4 makes an annoying clunking sound every time I go over a sharp bump (If it is a "smooth" one it won't do it).
I just replaced a front bearing thinking it was making that noise (the wheel was very loose, with a lot of in and out movement) but that noise is still there.
I also just repacked my inner CV boots with grease (as per kmverter's post in the maint. section) since they were leaking and noticed there was a little play in them. Could that be the source?
Everything else seems to be in good condition, the swaybar bushings, ball joints are tight etc.
I would appreciate any input on this.
Thanks

 

[rook]

(the wheel was very loose, with a lot of in and out movement) but that noise is still there.

Did you inspect the tie rod ends?

 

[Frenchie]

Yes I did, I just made sure they were tight by forcing them by hand in all directions. And the ball joints seemed ok, if that's what you mean. Unless I need to pry them with a crowbar to check them correctly?

 

[Uneek]

Is it happening when you're steering wheel is turned all the way to the left or right and you go over a bump? If so, add some grease to the steering stops.

 

[pipspeak]

Did you recently have the brake pads changed? My front brake pads were not shimmed properly and make a rattling noise every time I go over bumps.

 

[Frenchie]

Is it happening when you're steering wheel is turned all the way to the left or right and you go over a bump? If so, add some grease to the steering stops.

No it happens when I drive straight too.
I can hear it mostly at low speeds, below 30MPH.

 

[Frenchie]

Did you recently have the brake pads changed? My front brake pads were not shimmed properly and make a rattling noise every time I go over bumps.

Pads were changed recently but it makes a heavy clunking noise, not too certain if loose pads would do that?

 

[tattoo999]

Probably your shocks

 

[nc211]

This sounds exactly like the front strut rod bushings on the Lexus LS400's, exactly. But, since the 4runner doesn't have front strut rods, the other item that would cause this, every time, was the upper strut mount "shock mount". It is like a "POP" noise that you can kind of feel in the car?

Assuming the ball joints are ok "both the upper and lower", and the strut mounts are ok, then I'd take a closer look at your lower control arm bushings, then your uppers "if lower is ok". I say the lower first, because that's where your alignments are done, and over time, pushing and pulling on the bushing's rubber via the alignment bolts can create cracks in them.

How many miles do you have on the truck? What kind of conditions do you drive under "bad roads, heavy off roads, harsh winters", etc...?

Here's a Pdf of the front suspension set up.

Edit: I would attach it, but I can't due to size restrictions "what's up with that mods?"

 

[Frenchie]

. It is like a "POP" noise that you can kind of feel in the car?

Yeah pretty much, I kinda feel the clunking through the floor, but it's very light.

Just by looking at the upper strut bumpers everything seems fine, but is there a particular way to check this without raising the whole vehicle off the ground?

I have 145,000 km on it, and it's been driven in harsh winters we have here in Calgary. I doubt it was driven on rough roads since it's so clean but who knows. (I am the second owner, and bought it at 120,000km of use)

 

[SilverWolf]

I just did a search and found this thread. Frenchie, Im also from calgary gave an 04 runner with the same mileage and the EXACT same clunk you described. Did you ever find out what it was?

 

[dannyg]

Hey I had this problem and when I got my brake pads changed it got worse. I took it back and they added a shim and clips kit and that solved the problem
:guitar3:

 

[Frenchie]

I just did a search and found this thread. Frenchie, Im also from calgary gave an 04 runner with the same mileage and the EXACT same clunk you described. Did you ever find out what it was?

Yes I did. It ended up being the front sway bar bushings that were too worn out. I got some prothane bushings from JEGS and problem solved! Oh and it handled the road much better with those too.

Cheers

 

[SilverWolf]

I am going to check those bushings. Thanks Frenchie

 

[SoCalN8Tive]

This sounds exactly like the front strut rod bushings on the Lexus LS400's, exactly. But, since the 4runner doesn't have front strut rods, the other item that would cause this, every time, was the upper strut mount "shock mount". It is like a "POP" noise that you can kind of feel in the car?

Assuming the ball joints are ok "both the upper and lower", and the strut mounts are ok, then I'd take a closer look at your lower control arm bushings, then your uppers "if lower is ok". I say the lower first, because that's where your alignments are done, and over time, pushing and pulling on the bushing's rubber via the alignment bolts can create cracks in them.

How many miles do you have on the truck? What kind of conditions do you drive under "bad roads, heavy off roads, harsh winters", etc...?

Here's a Pdf of the front suspension set up.

Edit: I would attach it, but I can't due to size restrictions "what's up with that mods?"

Ahhh! I'm so glad I found this...my 05 T4R Sport does this...for the life of me I have not been able to track this down...Thanks for the great info...does anyone have pictures of what those bushings look like?

 

[Cdn4Runner]

Glad I found this as well. I'm in Calgary also and had this annoying clunk. Changed the sway bar bushings and it's gone!

 

[countrygoose]

04 4Runner Suspension Rattle/Thumping Fixed!!!

I heard the same front-end rattle as others have mentioned on my 125,000 mile 04 4Runner. I brought it to the dealership, and they said the front shocks needed to be replaced. This was true since I could feel the difference after the shocks were replaced. However this did not fix the rattle. I went under the truck and bumped the sway bar near the rubber mounts with my wrist and heard the same sound I hear while driving! I brought the truck back to the dealership and had the sway bar rubber mounts replaced, and not only did the rattle go away, but somehow to my excitement the steering tightened like it was brand new! If you bump the swaybar hard with your hand (or use a rubber mallet) and hear the metal-on-metal noise similar to what you hear while driving, I recommend you have the sway bar rubber mounts replaced...you will drive off of the dealership lot feeling like you just bought a new truck! Very happy!

 

[SnoboardingDave]

Is there a way to tell if the front bushings have gone bad? I have the clunking noise that comes with hard bumps, I'm thinking this could possibly be the problem. I'll change them anyway as mine's an 05 V8 w/ 86,000 miles.

 

[GoodSide]

I agree...it's a sway bar bushing.. Try grabbing the sway bar and push/pull on it back and forth with some force...you'll feel it. You can get to it close to the end link. Mine started about 20K ago on the drivers side on a trip to Texas.. I was worried so I took it in to a shop and asked them inspect the suspension for a clunk in the front. They couldn't find it but let me out to take a look (luckily) and I found it. They had my wheels off inspecting my rear brakes when I specifically stated it was a slight "clunk" in the front end. One way or another..they're always out to GETCHA!!

Just have to make sure you know the diameter of the sway bar and order a serviceable poly bushing from Summit or Jegs..I heard they put different diameter sway bars and you can't trust what is recommended. There are other threads on here about upgrading sway bar, sway bar bushing, and end links..

 

[SnoboardingDave]

GoodSide, it was indeed the sway bar bushings. I pulled on the sway bar back & forth like you suggested but it still felt tight, nothing out of the ordinary. However, I'd already ordered new ones so I installed them the other morning. Now it's nice and quiet again. This morning, I drove into work in downtown DC(terrible roads) with the windows open, hitting a few bumps on purpose & never heard a thing. That was driving me crazy for a few months now.