Suspension Clunking Everywhere!

[JoeToyota]

This thread is maybe a bit much, but it details me going through the diagnosis of this issue, and at the end I ask for recommendations. Thanks for reading! Or skip to the recommendation part if your not interested in the troubleshooting please.

I have a new to me 2006 V8 4runner sport 126k miles.
The car made clunking noises that were quite loud when I was inspecting it. I found the issue to be front sway-bar bushings worn. Lot of play, huge racket. Replaced them.

I replaced all end-links front to back as well, thinking the other slight clunk in the drivers rear was a worn end-link. Well the sway bushings making so much noise masked even more noise.

The Problem Continues

There is still major clunking in the front - both sides, drivers worse. Rear not as much, but still quite noticeable in the rear. Goes over big smooth bumps OK, rear it just sort of launches over bumps like a high sprung pick-up. Clunks are very obvious while driving 15ish mph over washboard bumps, like packed snow in residential streets. When the road is bad it sounds like the clunk rattles - as if something is very loose. Like sway-bar bushings, but not. Happens when driving straight or turning, faster or slower.

Troubleshooting

Heard a little noise when bounce testing it by bouncing on step bar, so I went through the list today. I want to rule everything out before I spend another dime on parts.
I check:
hatch,
rear seats,
bottle jack,
spare tire,
rear spring isolators,
every rear control arm bushing is good,
exhaust,
heat-shields,
wheel bearings,
front axles,
driveshafts,
front control arms - every bushing looks good and the ball joints are tight as can be.
Shocks are not leaking.
No play in steering or wheel at all.
Don't forget I replaced all sway-bar components...
Yes the wheels are torqued down.
Noise is independent of wheel speed.
Braking and accelerating have no affect.

Please tell me if I'm forgetting something, but my conclusion makes me think otherwise.

Tracking Down the Noise

So we are stumped and lower vehicle and do some more bounce test.... We just could not find this dang noise!! Probably a solid hour of bounce test, 3 of us had to take turns bouncing because the noise was coming from such a strange place.. And bouncing is a full body workout lmao.
We are honing in on the cluster of hydraulic XREAS lines just rear of the front drivers wheel well and VOILA it's clunking and you can put your hand on the hydraulic line and physically feel the vibration of the click/clunk. Nowhere else could we feel or hear (even with stethoscope) the click/clunk except the hydraulic line. It sounds exactly like all 4 of my shocks are totally shot when driving over bad surfaces. It all makes sense now.

I know another XREAS thread, but this was a tough puzzle to solve due to not being able to make all the noise as well as driving over bad surfaces does. Something that drives people to waste hundreds of dollars on unnecessary parts trying to solve a problem they cannot track down. There are so many suspension clunking threads and so many things to check.

Here's the thing.

The previous owner had an independent shop replace only the front XREAS shocks, about 15,000 miles ago. I was having trouble believing that such new shocks would be bad. After so much researching about XREAS and how touchy it is. Every single front-end suspension clunk thread, and I've finally found this https://www.toyota-4runner.org/1334808-post14.html comment in a thread about XREAS. This glorious man has come to the exact same conclusion (I hope) that I have - the shocks have lost fluid or pressure somehow and they are clunking. This conclusion we came to by finding an audible click and physical vibration in the XREAS hydraulic lines.

Has anyone heard of this symptom of a bad XREAS? I guess I assume the previous shop incorrectly replaced the front shocks and that they are now worthless along with the rest of the system? No recharging/filling the oil? Too bad I have the previous owners $1400 receipt from just about a year ago.

In Conclusion and Request for Recommendation

I will be replacing the shocks it seems. After I've had a Toyota tech confirm my suspicion. I want basically stock ride. Will NOT be lifting or leveling as long as I own it. If I want a beast off-road I will get a car specifically for that. All off-roading this truck does will be only necessary light off-roading. I tow a Lund Alaskan and a fish-house. Nothing more then a few thousand pounds.
Bilstein 4600? Remember this is a 99% city/highway vehicle. I want a shock that will last a long time, but perform. Probably been beat to death I know, but a lot of opinions here come from an off-roading point of view.

I appreciate your patience with me if you've gotten this far, I wanted this thread to expand on the comment that cmaj91 made which I linked, and I hope this helps someones future suspension noise diagnostics.

At the time of posting the noise has not been cured, I've not installed any new parts. That will change and this thread will be updated with results.

 

[Toyojay]

This thread is maybe a bit much, but it details me going through the diagnosis of this issue, and at the end I ask for recommendations. Thanks for reading! Or skip to the recommendation part if your not interested in the troubleshooting please.

I have a new to me 2006 V8 4runner sport 126k miles.
The car made clunking noises that were quite loud when I was inspecting it. I found the issue to be front sway-bar bushings worn. Lot of play, huge racket. Replaced them.

I replaced all end-links front to back as well, thinking the other slight clunk in the drivers rear was a worn end-link. Well the sway bushings making so much noise masked even more noise.

The Problem Continues

There is still major clunking in the front - both sides, drivers worse. Rear not as much, but still quite noticeable in the rear. Goes over big smooth bumps OK, rear it just sort of launches over bumps like a high sprung pick-up. Clunks are very obvious while driving 15ish mph over washboard bumps, like packed snow in residential streets. When the road is bad it sounds like the clunk rattles - as if something is very loose. Like sway-bar bushings, but not. Happens when driving straight or turning, faster or slower.

Troubleshooting

Heard a little noise when bounce testing it by bouncing on step bar, so I went through the list today. I want to rule everything out before I spend another dime on parts.
I check:
hatch,
rear seats,
bottle jack,
spare tire,
rear spring isolators,
every rear control arm bushing is good,
exhaust,
heat-shields,
wheel bearings,
front axles,
driveshafts,
front control arms - every bushing looks good and the ball joints are tight as can be.
Shocks are not leaking.
No play in steering or wheel at all.
Don't forget I replaced all sway-bar components...
Yes the wheels are torqued down.
Noise is independent of wheel speed.
Braking and accelerating have no affect.

Please tell me if I'm forgetting something, but my conclusion makes me think otherwise.

Tracking Down the Noise

So we are stumped and lower vehicle and do some more bounce test.... We just could not find this dang noise!! Probably a solid hour of bounce test, 3 of us had to take turns bouncing because the noise was coming from such a strange place.. And bouncing is a full body workout lmao.
We are honing in on the cluster of hydraulic XREAS lines just rear of the front drivers wheel well and VOILA it's clunking and you can put your hand on the hydraulic line and physically feel the vibration of the click/clunk. Nowhere else could we feel or hear (even with stethoscope) the click/clunk except the hydraulic line. It sounds exactly like all 4 of my shocks are totally shot when driving over bad surfaces. It all makes sense now.

I know another XREAS thread, but this was a tough puzzle to solve due to not being able to make all the noise as well as driving over bad surfaces does. Something that drives people to waste hundreds of dollars on unnecessary parts trying to solve a problem they cannot track down. There are so many suspension clunking threads and so many things to check.

Here's the thing.

The previous owner had an independent shop replace only the front XREAS shocks, about 15,000 miles ago. I was having trouble believing that such new shocks would be bad. After so much researching about XREAS and how touchy it is. Every single front-end suspension clunk thread, and I've finally found this https://www.toyota-4runner.org/1334808-post14.html comment in a thread about XREAS. This glorious man has come to the exact same conclusion (I hope) that I have - the shocks have lost fluid or pressure somehow and they are clunking. This conclusion we came to by finding an audible click and physical vibration in the XREAS hydraulic lines.

Has anyone heard of this symptom of a bad XREAS? I guess I assume the previous shop incorrectly replaced the front shocks and that they are now worthless along with the rest of the system? No recharging/filling the oil? Too bad I have the previous owners $1400 receipt from just about a year ago.

In Conclusion and Request for Recommendation

I will be replacing the shocks it seems. After I've had a Toyota tech confirm my suspicion. I want basically stock ride. Will NOT be lifting or leveling as long as I own it. If I want a beast off-road I will get a car specifically for that. All off-roading this truck does will be only necessary light off-roading. I tow a Lund Alaskan and a fish-house. Nothing more then a few thousand pounds.
Bilstein 4600? Remember this is a 99% city/highway vehicle. I want a shock that will last a long time, but perform. Probably been beat to death I know, but a lot of opinions here come from an off-roading point of view.

I appreciate your patience with me if you've gotten this far, I wanted this thread to expand on the comment that cmaj91 made which I linked, and I hope this helps someones future suspension noise diagnostics.

At the time of posting the noise has not been cured, I've not installed any new parts. That will change and this thread will be updated with results.

I've been fighting a similar clunk too on my sport. However, I've already deleted all of my XREAS stuff lol. I'm thinking it may be LBJ on mine. Just like yours, only does it on bumps at 10+ mph. Thought it was a good time to do F/R endlinks and all 4 sway bar bushings with poly.

For a stock ride, and deleting all the XREAS (highly recommended) 4600's are a great shock. You can find take off 5th gen parts as well, relatively new parts for a fraction of the price. I've heard the OEM 5th gen stuff rides nice on a stock 4th gen.

I'm fairly certain 2nd gen Tacoma 4600's will fit as well, but they may require a lift as I do know they are a bit longer. You can also go with 5100's, and leave them at zero. Very nice shock, and affordable.

 

[JVC8790]

I have a small clunk after deleting my Xreas that I think is a LBJ. I havent had time to track it down but I had a similar experience getting rid of a lot of noise with end links and then being left with one noise to diagnose.

I installed FJ Rear Springs and 4600's front and rear from a Tacoma TRD Offroad. It was a great upgrade over the old tired Xreas that I had. I also looked at some 5th gen stuff since there are plenty of guys taking theirs off to upgrade and are all too happy to sell their good condition stock setup for $50-200.

 

[Toyojay]

I have a small clunk after deleting my Xreas that I think is a LBJ. I havent had time to track it down but I had a similar experience getting rid of a lot of noise with end links and then being left with one noise to diagnose.

I installed FJ Rear Springs and 4600's front and rear from a Tacoma TRD Offroad. It was a great upgrade over the old tired Xreas that I had. I also looked at some 5th gen stuff since there are plenty of guys taking theirs off to upgrade and are all too happy to sell their good condition stock setup for $50-200.

That is exactly the issue I've been having with mine. At this point the only parts that aren't brand new suspension wise are the inner and outer tie rods, lower control arm bushings and LBJ.

Is yours just a clunk when hitting bumps, or something like a dip in the road?

 

[JVC8790]

That is exactly the issue I've been having with mine. At this point the only parts that aren't brand new suspension wise are the inner and outer tie rods, lower control arm bushings and LBJ.

Is yours just a clunk when hitting bumps, or something like a dip in the road?

I think mine is mostly from bumps, small potholes, etc. I haven't spent too much time looking into it.

When we installed my endlinks, sway bar bushings, and "lift" (Tacoma TRD Offroad) I thought I remembered it not making any noise for a few days and then coming back a little bit. Not sure if placebo, or if I just didn't hear it, or if my clunk is actually an endlink that wasn't tightened down enough. I might jack it up and give er the ol wiggle this weekend to see if I can identify anything obviously making this noise.

 

[Toyojay]

I think mine is mostly from bumps, small potholes, etc. I haven't spent too much time looking into it.

When we installed my endlinks, sway bar bushings, and "lift" (Tacoma TRD Offroad) I thought I remembered it not making any noise for a few days and then coming back a little bit. Not sure if placebo, or if I just didn't hear it, or if my clunk is actually an endlink that wasn't tightened down enough. I might jack it up and give er the ol wiggle this weekend to see if I can identify anything obviously making this noise.

I got ya, I know with mine I had issues after lifting with the front sway bar hitting the bottom of the coilover assembly. Had to use the sway bar relocate bracket. I'm sitting at just a hair over 3".

Might check the clearance there before buying any more parts.

 

[Karnivor707]

I got ya, I know with mine I had issues after lifting with the front sway bar hitting the bottom of the coilover assembly. Had to use the sway bar relocate bracket. I'm sitting at just a hair over 3".

Might check the clearance there before buying any more parts.

I think I might have this issue? I’m at I’m going to Estimate 3.5 lift in front and all sorts of new noises. Can u show a pic?

 

[Toyojay]

I think I might have this issue? I’m at I’m going to Estimate 3.5 lift in front and all sorts of new noises. Can u show a pic?

Its just a piece of aluminum that moves the bracket down about 1/2" and forward about the same. Its about a finger's width from the coil now and full compression, was touching before. Make sure you get a kit for a 4th gen, 5th gen brackets will not fit even though they look identical. Tried one from a friend first before buying lol. I used the supreme suspension brand from Amazon, was $30.

<a href="https://ibb.co/NYHMkcM"><img src="https://i.ibb.co/6sfkpjk/slh-sus34.jpg" alt="slh-sus34" border="0"></a>

 

[inscarguy]

My suggestions are these:

1- make sure the front strut mounts are ok, They can fail and give a clunking noise.

2- put the car in the air and get a short prybar and check all bushings, joints etc and look for play. most likely there will be something worn.

3-did the fronts get replaced with another set of xreas? Maybe the new system was installed incorrectly, maybe the unit on the frame rail is no good.

Good luck.

 

[JoeToyota]

My suggestions are these:

1- make sure the front strut mounts are ok, They can fail and give a clunking noise.

2- put the car in the air and get a short prybar and check all bushings, joints etc and look for play. most likely there will be something worn.

3-did the fronts get replaced with another set of xreas? Maybe the new system was installed incorrectly, maybe the unit on the frame rail is no good.

Good luck.

1 - Strut mounts look OK, cannot tell if they were replaced along with front shocks. They are tight though and the rubber doesn't look cracked.

2 - Did this - Everywhere.

3 - The front shocks were each replaced with XREAS. (about $480 each) by an independent shop - first clue something might have gone wrong during installation. Second clue was that according to Toyota, and everything else I've read is that the shocks must be replaced in diagonal pairs. If there was fluid loss due to bad rear shocks (hard to tell this time of year, though both rear shocks do clunk and they have 125k on them), then they essentially ruined the front shocks the moment they were installed. Everything I've gathered from this is that the shop didn't know what they were dealing with unfortunately. Checking receipts it was less then a year ago and only about 5k miles ago.

If the unit on the frame rail is bad, the whole system would need to be replaced - Toyota says too much fluid loss will occur if system is opened more then once. I can still get a set of 4 non-XREAS shocks for the price of 1 center damper, or nearly any single piece of this system.

Thanks.

 

[inscarguy]

1 - Strut mounts look OK, cannot tell if they were replaced along with front shocks. They are tight though and the rubber doesn't look cracked.

2 - Did this - Everywhere.

3 - The front shocks were each replaced with XREAS. (about $480 each) by an independent shop - first clue something might have gone wrong during installation. Second clue was that according to Toyota, and everything else I've read is that the shocks must be replaced in diagonal pairs. If there was fluid loss due to bad rear shocks (hard to tell this time of year, though both rear shocks do clunk and they have 125k on them), then they essentially ruined the front shocks the moment they were installed. Everything I've gathered from this is that the shop didn't know what they were dealing with unfortunately. Checking receipts it was less then a year ago and only about 5k miles ago.

If the unit on the frame rail is bad, the whole system would need to be replaced - Toyota says too much fluid loss will occur if system is opened more then once. I can still get a set of 4 non-XREAS shocks for the price of 1 center damper, or nearly any single piece of this system.

Thanks.

Sounds like your xreas system has failed somewhere. It looks like its a good idea to start looking at a new system. In in the process of doing that now.

 

[JoeToyota]

Well the final test was conducted this week by removing the lower bolt on the rear shock that was making the most noise, when it was nearly fully extended it looses all pressure for about 1" of travel and clunks.

Problem solved.

New Bilstein 4600s were installed yesterday. Truck rides fine now. 0 noises. It's a pity the previous owner had the XREAS serviced anywhere but Toyota.

Thanks for tuning in.

 

[Toyojay]

Well the final test was conducted this week by removing the lower bolt on the rear shock that was making the most noise, when it was nearly fully extended it looses all pressure for about 1" of travel and clunks.

Problem solved.

New Bilstein 4600s were installed yesterday. Truck rides fine now. 0 noises. It's a pity the previous owner had the XREAS serviced anywhere but Toyota.

Thanks for tuning in.

Glad you got it sorted out. Huge bummer for the PO, lots of $$$ wasted on the XREAS.

 

[pnwcruiser]

Glad you got it sorted out. Huge bummer for the PO, lots of $$$ wasted on the XREAS.

Ya, XREAS is total garbage. We had it replaced by a Toyota dealership at 65k and then at 110k it failed again, so we just said screw it and had the XREAS removed went with OME spring/shock. Imagine how many 4th gen 4Runners are on the road with blown XREAS systems. That's a LOT of unsafe rides out there. I'm kinda surprised Toyota has not had a recall on that suspension system yet.

 

[Toyojay]

Ya, XREAS is total garbage. We had it replaced by a Toyota dealership at 65k and then at 110k it failed again, so we just said screw it and had the XREAS removed went with OME spring/shock. Imagine how many 4th gen 4Runners are on the road with blown XREAS systems. That's a LOT of unsafe rides out there. I'm kinda surprised Toyota has not had a recall on that suspension system yet.

Toyota is real good about issuing TSB's over recalls but I can't say I've ever seen one fail so badly to the point of it being "unsafe" per say. They do have more body roll and what not with bad shocks, and it makes a damn mess. On paper its a good system, but it doesn't work for the long haul. I feel like it would be a more successful system if it were more serviceable. Not being able to get the fluid, and having to replace at minimum 2 shocks and lines is just ridiculous. Toyota knows best though, right? :lmao:

Still looking for my clunk, I've kind of stopped worrying about it for the time being. Pretty sure its the LBJ, can't think of anything else I haven't already messed with. They are compression style, so its unlikely they'll come apart and I greased them so we'll see lol.

 

[JoeToyota]

Still looking for my clunk, I've kind of stopped worrying about it for the time being. Pretty sure its the LBJ, can't think of anything else I haven't already messed with. They are compression style, so its unlikely they'll come apart and I greased them so we'll see lol.

Just need to take the wheel off and pull 2 bolts to get a really good check on that LBJ.

Lift truck.
Remove wheel.
Remove the two 17mm (I think) bolts holding the lower control arm to the spindle.
Lift up the spindle a couple inches using a jack under the rotor.
Grab the bracket that the LBJ bolts to (which you just unbolted from spindle) and see how the ball-joint feels.

Should give you a decent enough idea on the condition of the ball-joint.