Popping noise during articulation

[Koddo]

Howdy everybody.

I take my 10' Trail w/ KDSS offroading just about every weekend. I drive carefully and never abuse it, but I do get into some medium difficulty areas. So recently I've started noticing a popping noise coming from the front suspension during medium-heavy articulation. I can feel a slight vibration in the steering wheel when it makes the popping metal on metal sound.

I installed bilsteins about 1.5-2 years ago and made sure to tightening all bolts to spec and reapply threadlock on ones that had it. I've checked the bolts again to see if something is loose but couldn't find anything. I've taken it into the dealership twice and they couldn't replicate or find anything wrong.

Any ideas? The noise does not sound good and is definately becoming more frequent. About 6-9 months ago I would hear the pop only infrequently and only during heavy articulation. It does it louder now, more frequent, and with less articulation. It does not happening with daily on road driving - going over speed bumps or making turns where the two roadways are not level and cause a little articulation.

Thanks

 

[4Running303]

Its probably your KDSS/front swaybar. Mine does it occasionally as well.

 

[Jono.ful]

Definitely sway bars

 

[wfo9]

Could be anything. Here is the stuff i usually check in the front for popping.

- Tie rod ends
- Inner tie rods
- Sway bar links and bushings
- UCA ball joint/uniball
- UCA bushings..
- shock mounts (bushings/ bearings)
- LCA bolts and bushings

Some noise is normal... but mine is usually silent when everything is fresh and clean.

 

[Koddo]

Found out what it was....my RCI steel skidplate. Of course its the last thing I check...went through every bolt and component of the front suspension, found nothing wrong. Took the skidplate completely off and found some nice articulation exercises close to home, everything was completely quiet. During this I conveniently remembered in the back of my head that the popping noise became much worse after I kissed a rock with my front skidplate. Apparently the medium-heavy articulation made the -slightly- loose skidplate do a snappy popping noise very similar to that of loose suspension components. After looking at the RCI hardware I decided to use some beefier washers and add a generous amount of threadlock. I tightened the skidplate bolts to 30 lbs....couldn't find the proper torque, but was scared of breaking them. If the skidplate starts to make noise again I'll go from the 8.8 bolts RCI included to 10.9 or 12.9 and really torque them down.