front end clunk

[Misterquad]

Let me go out on a limb and say that KDSS clunking is caused by low pressure in the system. This is caused by leaks or tampering.

On a side note, I also sourced all the parts if needed through Toyota of Dallas online parts department if you wanted to replace the whole system like new. I realized by reading the instructions, finding all the sources for parts and having some schooling in hydraulics that most of us that can install a lift can fix our own KDSS.

I did consider removing the whole system and going to normal sway bars. But once I learned my way the KDSS functions I would much prefer to keep it.

The issues with removing the KDSS.
1. I could not figure out how to disable the dash light. I unplugged the KDSS. Nope. I pulled the fuse. Nope. I talked to the Toyota Tech about disabling the light with their computer. Nope.

2. The rear sway bar assembly off a regular 4Runner or FJ won't work. The mounting points are not there. The front sway bar can be replaced but not the rear.

3. I usually trade vehicles every 2-3 years and don't want to lose the value of this truck by removing KDSS.

 

[Marcocopuffs]

I noticed something that could be the source of the problem. It appears that the sway bars has a lot of side to side play in regards to the bushings and end links. I took my car off roading and inspected the KDSS sway bar in the front. It looks like the dirt has been rubbed off on both side where the bushings attach front the end links to the sway bar. This could indicate some "wiggle" room and could be the source of the clunk. I'm hoping someone with stock un-altered KDSS suspension could chime in... if your sway bar is completely dirty near the end links after going off road a bit it might be I didn't tighten those end links down enough... my problem is i literally couldn't tighten the bolts anymore. Please see the "cleaned" area where my sway bar is connected.

 

[96r50]

I would say that is just from the normal up and down cycling of the front suspension. As your LCAs droop those sway bar mounting points get closer to the centreline of the truck which wipes the bar. Simply driving down a bumpy road would most likely have the same effect. The bushing is there to allow for play and give in the system. You don't have to crank those bolts down super tight; all they need to do is clamp that bushing in place.

 

[Jeremy556]

I noticed something that could be the source of the problem. It appears that the sway bars has a lot of side to side play in regards to the bushings and end links. I took my car off roading and inspected the KDSS sway bar in the front. It looks like the dirt has been rubbed off on both side where the bushings attach front the end links to the sway bar. This could indicate some "wiggle" room and could be the source of the clunk. I'm hoping someone with stock un-altered KDSS suspension could chime in... if your sway bar is completely dirty near the end links after going off road a bit it might be I didn't tighten those end links down enough... my problem is i literally couldn't tighten the bolts anymore. Please see the "cleaned" area where my sway bar is connected.

I had a clunk that replacing those outer and the inner bushings resolved. The bushings had been greatly enlarged after 100K miles - I could stick a screw driver between the bushing and swaybar on the outer ends and move the swaybar in the inner bushing vertically with a prybar. After replacing all 4, no more clunk when going over uneven bumps.

 

[adam2562]

I had a clunk that replacing those outer and the inner bushings resolved. The bushings had been greatly enlarged after 100K miles - I could stick a screw driver between the bushing and swaybar on the outer ends and move the swaybar in the inner bushing vertically with a prybar. After replacing all 4, no more clunk when going over uneven bumps.

i think everyone should try this first.. yes even if you see a little leak from your cylinder. i don't have any leaking period from either of my cylinders so when i get around to it this is what i'm gonna do first.

 

[Jivewalker]

Old post, but did you do bushings and did it fix your clunk? I have some front end clunking as well and was thinking the bushings may need replaced.

 

[skinny420]

Old post, but did you do bushings and did it fix your clunk? I have some front end clunking as well and was thinking the bushings may need replaced.

I'm getting a noise but not sure if it is the same as what y'all are describing. I only get my cruuunnnk noise when turning right into a driveway. I have to be going "fast". That is faster then you would normally be going and turning into a driveway / uphill parking lot entrance. Point is that the left front is experiencing an abnormal (for on road) amount of flex/travel.

Did you replace KDSS sway bar bushings? Did it solve the issue?

 

[Okusputokus]

Whiplash - I sent you a PM.

Next thing, here is the KDSS bleeding instructions for a Lexus. The 4Runner has one port not two but the process is the same.

GSIC - Global Service Information Center

I have the Toyota specific instructions at home.

View attachment 142562

I'm facing serious clunking now. Wondering if you'd be interesting in selling your pump kit. I cannot seem to find one priced the same as when you bought it.

Thanks

 

[northcoast]

I'm facing serious clunking now. Wondering if you'd be interesting in selling your pump kit. I cannot seem to find one priced the same as when you bought it.

Thanks

Do the bushings first. Seems like that simple fixed has solved the KDSS clunks, including mine.

 

[Wolfman’s Brother]

How much did the charge and re-pressurize the KDSS system?

Enough that I’m really glad I wasn’t successful in my search for a Trail Premium with KDSS equipped.

 

[dakgildea]

Could be a loose LCA bolt. I had a clunk on the driver side and that was the cause.