front end clunk

adam2562

adam2562

New member
Front end clunk KDSS

Anybody with KDSS get a front end clunk over uneven surfaces? i felt it start forming before i put my updated suspension on.. and with the last few trips.. mainly Uwharrie's bumpy a$$ roads lol.. i felt it loosen up.. i'm almost positive that i just need to replace the sway bar end bushings and i'm probably going to also replace that brace that holds onto the sway bar from the kdss cylinder and the bushing with it.
Anybody else with a possible fix if you've had it and solved it?
 
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adam2562 said:
Anybody with KDSS get a front end clunk over uneven surfaces? i felt it start forming before i put my updated suspension on.. and with the last few trips.. mainly Uwharrie's bumpy a$$ roads lol.. i felt it loosen up.. i'm almost positive that i just need to replace the sway bar end bushings and i'm probably going to also replace that brace that holds onto the sway bar from the kdss cylinder and the bushing with it.
Anybody else with a possible fix if you've had it and solved it?
Click to expand...

i don't the this is exclusive to t4r with kdds, a lot of guys with TRDpros are also reporting same thing, including me. usually only when the suspension is cold...if that makes sense
 
drsus said:
i don't the this is exclusive to t4r with kdds, a lot of guys with TRDpros are also reporting same thing, including me. usually only when the suspension is cold...if that makes sense
Click to expand...

that does make sense.. when it gets warm out, i'm going to take off all the skids and see if maybe my front skid got bent up which it has but enough to where the sway bar taps it.. but i doubt it on the lighter bumps i hit.
 
Aftermarket uca's? I just did my uniballs over Christmas, was 3/16's of slop in them causing a lot of clunk
 
I have a 14 TEP with kdss that clunks when I drive over uneven surfaces while turning left. I have not done anything to the suspension (yet). I guess I should take it to the dealer to document the issue before installing the Icon lift.
 
Yep. Replaced all 4 bushings a few weeks ago at 100K miles. It cleared up my only remaining suspension clunk.
 
I fixed my clunk about 3 weeks ago and so far it has stayed gone. And I have tried my best to make it clunk again.

From the time I bought it, it clunked ocassionally when it was cold. When it was warm it was okay. Then the shop that swapped out my rear springs released some pressure from my KDSS. Then I noticed more clunking that irriated me more. And as it got colder it clunked more frequently. Then when it got below 40 degrees the KDSS light came on. And let me comment that the truck never seemed as smooth offroad as my FJ did. I even had my FJ friends test drive it and they commented that it felt abnormal but not obviously bad. So yes, it clunked ocassionally and was not truly smooth as expected offroad.

So last December when the KDSS light came on, I was able to get the KDSS system tested and the pressure was roughly 1.5MPa and it should have been closer to 3MPa. Now, the pressure has been corrected and the clunking has been gone ever since. The ride has never been better. I love it now.

That was what worked for me but I tried several other fixes during the process. Because when I bought the truck used on Ebay and it came lifted with extended travel Icons and LR UCAs. So, I changed the bushings in the UCAs and it seemed better but not as good as I expected. Then I swapped the Icons for OME and it really did not changed. And so I just lived with it until the KDSS light came on. Then I decided to get it fixed or I was going to sell this truck.

Looking back on my experience, I am led to believe that the previous owner's lift installer must have released some KDSS pressure too. And now I think that is why he sold it. Because when I want to get it fixed several of the dealers said they could not fix the pressure or they wanted to install a brand new KDDS for $3,200.

If I were you and I was sure it has not been tampered with then I would look for a hydraulic leak on the KDSS cylinders or lines. Also, the LR UCAs had some sold that had a mis-sized bushings that they provide replacement parts for.

Good Luck.
 
well i dont have aftermarket UCA's but i'll check my upper arms.. the bushings replacement on the swaybar is the cheapest thing to try first... if that or taking off the skids don't do it.. i'll replace my UCA's
 
Jeremy556 said:
Yep. Replaced all 4 bushings a few weeks ago at 100K miles. It cleared up my only remaining suspension clunk.
Click to expand...

i thought it was 3 bushings up front on the sway bar? 1 at each end and then the one on the big stabilizer connected to the kdss cylinder?
 
I Googled this clunk over the past few months. And saw one guy that replaced the UCAs under warranty and the problem continued. Then he re-torqued the skids and it stopped. I am just offering a suggestion.
 
adam2562 said:
i thought it was 3 bushings up front on the sway bar? 1 at each end and then the one on the big stabilizer connected to the kdss cylinder?
Click to expand...
There are 2 of those. One on the bottom of the KDSS piston, and an identical one on the passenger side where the fixed sway bar mount is. In the pic below, you can see the 4 bushings and the fixed sway bar mount, the KDSS piston is not shown (on previous page)
1-12-2015%202-23-03%20PM.png
 
Misterquad said:
I Googled this clunk over the past few months. And saw one guy that replaced the UCAs under warranty and the problem continued. Then he re-torqued the skids and it stopped. I am just offering a suggestion.
Click to expand...

that's good to know.. i'll obviously do that last but keep that in mind
 
Misterquad said:
I fixed my clunk about 3 weeks ago and so far it has stayed gone. And I have tried my best to make it clunk again.

From the time I bought it, it clunked ocassionally when it was cold. When it was warm it was okay. Then the shop that swapped out my rear springs released some pressure from my KDSS. Then I noticed more clunking that irriated me more. And as it got colder it clunked more frequently. Then when it got below 40 degrees the KDSS light came on. And let me comment that the truck never seemed as smooth offroad as my FJ did. I even had my FJ friends test drive it and they commented that it felt abnormal but not obviously bad. So yes, it clunked ocassionally and was not truly smooth as expected offroad.

So last December when the KDSS light came on, I was able to get the KDSS system tested and the pressure was roughly 1.5MPa and it should have been closer to 3MPa. Now, the pressure has been corrected and the clunking has been gone ever since. The ride has never been better. I love it now.

That was what worked for me but I tried several other fixes during the process. Because when I bought the truck used on Ebay and it came lifted with extended travel Icons and LR UCAs. So, I changed the bushings in the UCAs and it seemed better but not as good as I expected. Then I swapped the Icons for OME and it really did not changed. And so I just lived with it until the KDSS light came on. Then I decided to get it fixed or I was going to sell this truck.

Looking back on my experience, I am led to believe that the previous owner's lift installer must have released some KDSS pressure too. And now I think that is why he sold it. Because when I want to get it fixed several of the dealers said they could not fix the pressure or they wanted to install a brand new KDDS for $3,200.

If I were you and I was sure it has not been tampered with then I would look for a hydraulic leak on the KDSS cylinders or lines. Also, the LR UCAs had some sold that had a mis-sized bushings that they provide replacement parts for.

Good Luck.
Click to expand...

How much did the charge and re-pressurize the KDSS system?
 
adam2562 said:
well i dont have aftermarket UCA's but i'll check my upper arms.. the bushings replacement on the swaybar is the cheapest thing to try first... if that or taking off the skids don't do it.. i'll replace my UCA's
Click to expand...

Please let us know if the swaybar bushings help or not.
 
i will.. i don't plan on doing them until it warms up so maybe a cpl months at least.. but either way, i'll definitely let you guys know
 
Last edited:
Misterquad said:
I actually found the Toyota HP pump on Ebay for $500 and bought the AHC fluid at Toyota for $45. The Service Manager at one dealership printed the instructions for me and so I did it myself.
Click to expand...

Misterquad, I am sitting on a $1600 KDSS repair/service bill, and would love to get any info you could provide on what you bought, and the service procedure.

-Pump Part Number
-ACH Fluid Part Number and Cost
-Bleeding Instructions

If the instructions aren't digital, and I could somehow get hard copies from you, I would be happy to digitize them, and post them for everyone. Photos would work as well.

FYI - This thread recently opened and the OP is experiencing the same clunk due to a leak in the front KDSS actuator and loss of pressure in the KDSS system.

http://www.toyota-4runner.org/5th-gen-t4rs/186289-serious-kdss-problem.html

Any info we could get from you would be a huge help!

Thanks!
 
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