Dealership Warranty Issue: Replacing X-REAS

[4Given]

Compromised X-REAS System = Clunking-Knocking???

I’m looking for official Toyota Technical documentation regarding servicing the
X-REAS system, for my 2008 Urban Runner (Sport).

Question: Can a strut or shock be disconnected for service or replacement and maintain the integrity without having to replace the entire X-REAS system?

On two separate occasions my struts and shock were disconnected. As a result, I suspect the X-REAS system may have been compromised.

Background: I have been experiencing annoying clunking-knocking noises coming from the Left Rear Shock area for over 4 years. This noise started after the Dealership installed Cornfed Front lift spacers. At that time (2008), the Tech removed the two front struts to install the spacers.

This clunking-knocking noise increased over time and in 2010, I took it to the dealership to chase down the noise. They found a leaking Left Rear shock that was "misting". They replaced the shock. After replacing the shock the noise all but faded away. Then slowly, it started up again; steadily increasing over the months. It's now it’s 2013 and the noise is louder than ever.

Summary: Is the clunking-knocking noise a result of the X-REAS system being compromised by disconnecting the struts and shock?
If so, does anyone have documentation regarding servicing of the system?

Thanks for your time.

 

[BlackWorksInc]

I'll have to try and get you the .pdf for R&R the XREAS system when I have a chance this week.

But it is actually possible to remove individual components of the system without draining the system of fluid or introducing air into the system. There are actually designated disconnect points along the system that have check valves to allow removal and replacement of components. That being said, Toyota recommends you replace them in linked pairs (i.e. front left strut to right rear strut and central cylinder.)

I touched on it briefly when I did my install, http://www.toyota-4runner.org/4th-gen-t4rs/84725-zombie-truck-2-0-mpav-build-4.html

 

[4Given]

Info from J. A.'s Toyota 4Runner site

Here's some info from what appears to be a 2003 service document on J. A.'s Toyota 4Runner site:

Precautions for Replacing X-REAS Parts —
Before removing or reinstalling a component, make sure that the front or rear shock absorber to which the component is connected is in the fully extended state.
An individual component may be replaced only when the system is repaired for the first time, provided that there is no oil leakage. During the second and subsequent repairs, the entire system (consisting of front shock absorbers, rear shock absorbers, center control absorbers, and tube assemblies) must be replaced as a unit, because of the likelihood of oil leakage from the joints.
For details, refer see the 2003 4Runner Repair Manual (Pub. No. RM1001U).




Considering my was disconnected 3 times (2 front & 1 rear) I'm thinking my system has been compromised.

 

[LTDSC]

I'll have to try and get you the .pdf for R&R the XREAS system when I have a chance this week.

But it is actually possible to remove individual components of the system without draining the system of fluid or introducing air into the system. There are actually designated disconnect points along the system that have check valves to allow removal and replacement of components. That being said, Toyota recommends you replace them in linked pairs (i.e. front left strut to right rear strut and central cylinder.)

I touched on it briefly when I did my install, http://www.toyota-4runner.org/4th-gen-t4rs/84725-zombie-truck-2-0-mpav-build-4.html

When you disconnected the rear shock at the point circled in your pictures, how did you remove the rest of the hosing so its not just hanging there? Is there another connection point to where you can disconnect as well?

 

[BlackWorksInc]

There's a disconnect hidden where the frame curves downwards towards the front.

 

[Gatafly]

I had clunking both front and rear and it drove me nuts. It slowly got worse and I also noticed a change in the ride. Happened slowly over time so did not really realize it. The XREAS and never been serviced and none of the shocks or connections were leaking. I think seals just got worn and they did not perform anymore. Put 5100's in and the clunking disappeared.

 

[PwAg]

I just went through a similar issue with XREAS on an '08 with 45k miles. Clunking in rear-driver side, sometimes faintly in the front right. Especially in colder temps.

Only after uninstalling the front right XREAS shock did I notice grease dusting on upper engine-facing side of shock body.

I spent $325 for Front & Rear Bilstein 5100 shipped, installed myself in 7hrs. Clunking gone. Relatively straight-forward and quite inexpensive.

Unless you are covered under warranty, I would skip XREAS replacement and move on to an aftermarket oem strut.