Toytec Front Coilover Leak / Clunk Noise?

[tay4R]

So back in 4/17 I noticed that my front drivers side shock was leaking and this cap popped off and was loose along the shaft. It leaked more than a "normal" amount (Toytec stated this was normal) as the entire shock and coil was coated (pics show after I power washed it a week before as I didn't notice the leak yet). Anyways, I've still been driving on it since then and today just noticed that the top nut is looser on the driver's side as I can easily turn the washer just below it (circled in pic). Passenger side is solid and can't be turned. Has anyone ever experienced any leakage/issues with Toytec Boss coilover shocks?

Maybe on a related note, there has been a nasty clunking noise on the front drivers side for many months. Happens at slow speeds like in parking lots when in reverse at full turn. Here is some info/what I have checked:

2004 SR5 4WD V6 ~180k
Toytec Boss suspension kit (installed ~20k ago, 3/16)
1" Toytec body lift (checked mounts for clunk noise, all tight)
Toytec diff drop (checked for clunk noise, all tight)
SPC Light Racing LCA (boot and ball joint look good)
285/70/17 BFG KO2 w/ Method Mesh Wheels (+ spidertraxx)
Mevotech LCA's installed (10/16 ~10k ago)
New OEM CV's installed (4/17 ~3k ago, rockauto cv's were binding at full droop)

Removed:
Sway bar
Skid plates
Demello Bumper


I've also checked the steering bump stops since the noise happens at full turn. They are greased up and the noise also happens when the bump stops are not touching. I'm kinda stumped about the noise. One other culprit I can think of could be the tie rod ends. They are original and have a little play in the ball joints but nothing I could imagine would create the clunk.

Would love all your guys' thoughts/input. Here are some pics of the coilover:

 

[2016 4Runner SR5]

Photobucket links don't work. Post the actual pictures rather than links.

 

[tay4R]

Photobucket links don't work. Post the actual pictures rather than links.

Thanks, pics have been updated.

 

[2016 4Runner SR5]

Yeah, that shock is shot. Absolutely not normal at all.

 

[tay4R]

Yeah, that shock is shot. Absolutely not normal at all.

What specific issue makes you say that? The cap popped off? Oil leaking? Loose top nut?

 

[2016 4Runner SR5]

What specific issue makes you say that? The cap popped off? Oil leaking? Loose top nut?

Top nut is no big deal, can just tighten that back down. The fact the shock is leaking and the body is falling apart is a big issue.

 

[jrm]

I think youre

going to need to remove the coil for the strut to get an idea of whats going on. My take would be that the strut lost pressure thus blowing the seals and fluid...

any warranty or replace info from toytec?

 

[Bumbo]

That shock is toast :rip:... time for a long travel upgrade :lookout:

 

[tay4R]

going to need to remove the coil for the strut to get an idea of whats going on. My take would be that the strut lost pressure thus blowing the seals and fluid...

any warranty or replace info from toytec?

That's my plan for this weekend to disassemble the coilover and test the shock. Toytec said the cap coming up a bit is very common. Toytec said it doesn't look blown, but to try for warranty I have to buy a new shock and then send them back the old one so they can test it. A new shock is $200.

That shock is toast :rip:... time for a long travel upgrade :lookout:

Christmas is coming up....:hungry:

 

[ToyTec Lifts]

Hey bud, sorry you are going through this. This definitely could be brought to the support team's attention. Call us to see if it's under warranty.

Email those photos to: [email protected]

 

[tay4R]

Toytec was great in helping me order and ship a new shock on Wednesday before the holiday. Going to replace the shock and tie rod ends together and get an alignment after. Toytec said they might be able to warranty to the shock after I send it back since it hasn't quite been 2 years yet.

Also diagnosed the clunk as the lower control arm cam bolts not torqued appropriately. Alignment shop probably only used an impact and didn't torque them all the way. A quick tightening and no clunk! Should've checked that a long time ago...

Thanks for everyone's input and help and hope you all have an amazing holiday weekend.