TRD Pro Clunk

[stir_fry_boy]

Mine is not a clunk, but kind of a squeaking, only in small changes On/off road. If it's a curb, I don't hear it. I do hear the squeaking when it's hot as well, it's been over 104 consistently here.

It's getting worse, and more left side vs right (if it is coming from the right at all). Going to mention it to the dealer doing my 15,000 mile service to take a look at it and document it.

 

[The White Brick]

Mine is at the dealer right now for this. They called to say that there is a tech number to call for suspension clunk issues and that they would call me back.
Will update.

 

[The White Brick]

I just talked with the dealer on the phone. They said my TRDPRO is ready to be picked up.
They said Toyotas position on the clunk is that it's normal. I asked why then is the top left shock bushing loose compared to the right side. He didn't know but that Toyotas position is nothings wrong. I'll buy the pieces needed to repair this and repair it myself. The insulator bushing should be compressed just like the right side. I shouldn't be able to rotate it by hand or move it up and down on the shock shaft as it is. Maybe a disagreement between Bilstein and Toyota on responsibility that is causing this position.

 

[TRD4runnin]

I just talked with the dealer on the phone. They said my TRDPRO is ready to be picked up.
They said Toyotas position on the clunk is that it's normal. I asked why then is the top left shock bushing loose compared to the right side. He didn't know but that Toyotas position is nothings wrong. I'll buy the pieces needed to repair this and repair it myself. The insulator bushing should be compressed just like the right side. I shouldn't be able to rotate it by hand or move it up and down on the shock shaft as it is. Maybe a disagreement between Bilstein and Toyota on responsibility that is causing this position.

I will notify my contact. This is unacceptable, and they need to fix it!

 

[The White Brick]

Late update: I just returned home from the dealer.
I requested to speak to the service manager when I picked up the truck.
I showed him the visible condition of my shock mounting and he agreed it was not right. He called Toyota back and explained it is NOT normal and now they have agreed to replace the whole shock/spring strut. He thinks the washer on the bottom side has failed, but he's not sure of how the underside is assembled.
Is it nut,washer bushing or a threaded washer,bushing. The tip top stem of the shock is up so high that it is only about 1/16th in. away from a fastener head on the inner fender and may be hitting it under driving conditions.
I explained my feeling that Toyotas original position may be a result of a disagreement between Bilstein and Toyota on responsibility. He was puzzled by their position as well.
I'll be taking it back in when the strut arrives.
The service manager at the dealer was very positive and helpful after he saw the condition and I thank him for that but at this point in time will go unnamed.

 

[The White Brick]

Thanks to TRD4runnin for any calls he may have made.

 

[Bevo]

Glad you will be getting some resolution to your problem White Brick. I still think that your issue is different from the one that others have been seeing. We did not have anything visibly wrong with our front ends. It will be interesting to see if your clunk reappears when the temps drop.

 

[The White Brick]

Update: Pro Clunk has been fixed. I picked up the truck friday after a week and a half. Toyota called the dealer back and had me bring it in as they did not want me driving it with the previously explained condition. They gave me a new Highlander loaner which I thought was not bad. The dealer wanted to disassemble the spring/shock assembly to see what has failed but Toyota wanted the unit back untouched. A few interesting notes as stated by the dealer.
When the truck is on the lift the spring/shock assembly extends and the condition is not seen. When the unit is taken out of the truck it is also fully extended and the condition is also unseen.
The condition is only detected by looking at the top shock mount with the truck sitting on the ground.
The truck also rides better because I got back the shock control on the front left.
I would like to think that I'll find out the details of what the exact failure was.
To those of you who have taken your runner in for this, let me say that my dealer at first missed the issue because the first thing they did was put the truck on the lift to look for the problem.
Hope this helps others.

 

[TRD4runnin]

Update: Pro Clunk has been fixed. I picked up the truck friday after a week and a half. Toyota called the dealer back and had me bring it in as they did not want me driving it with the previously explained condition. They gave me a new Highlander loaner which I thought was not bad. The dealer wanted to disassemble the spring/shock assembly to see what has failed but Toyota wanted the unit back untouched. A few interesting notes as stated by the dealer.
When the truck is on the lift the spring/shock assembly extends and the condition is not seen. When the unit is taken out of the truck it is also fully extended and the condition is also unseen.
The condition is only detected by looking at the top shock mount with the truck sitting on the ground.
The truck also rides better because I got back the shock control on the front left.
I would like to think that I'll find out the details of what the exact failure was.
To those of you who have taken your runner in for this, let me say that my dealer at first missed the issue because the first thing they did was put the truck on the lift to look for the problem.
Hope this helps others.

What's the dealership name again? I can have my contact call them.

 

[The White Brick]

Pauly Toyota in Crystal Lake, Il.

 

[WTERUNNER]

So does this problem affect the TRD PRO Suspension kits? I have one on order to be installed by my dealer in a few weeks.

 

[The White Brick]

I do not know the answer to this. I do know that the dealer replaced my LF spring/shock assembly from a complete set of 4 that was sent from Toyota. Single units are not available as yet. I looked at the unit removed but the failure is hidden under the rubber bellows cover of the shock shaft and what ever happened can not be seen.

 

[WTERUNNER]

Hmm, ok, guess I'll just have to let them install it and hope for the best.

 

[PitbullRescuer]

Glad you got it resolved. Please post some updates as you accumulate some miles on the new part. In reading your update I'm a little confused. Are they saying the issue was with the rubber top hat (upper shock mount) or with the shaft inside the shock itself? Either way I'm glad you got some resolution and hopefully it trickles down to everyone else.

 

[The White Brick]

I have not bothered to say what I think the issue was even with my engineering and automation background because it would only be speculation without being able to see the disassembled components myself.
I don't think the issue is with the shock internally.
I think the problem was central to the rubber insulator bushing and backup washer that is on the bottom side of the upper spring mount. The bushing and washer fit inside a recessed pocket in the upper spring mount and can't be see after the unit is assembled. After thinking about how the assembly process in undertaken I think that IF the backup washer becomes misaligned on the shock shaft as the top compression nut is tightened, the washer could catch on the side of the recess as it is pulled into the recess. This could cause the washer to be deformed and damaged to the point that it does not back up and compress the rubber bushing on the bottom side of the mount as it should. Since it is pulled into the recess and would be hidden by the rubber bellows around the shock shaft the assembler would not know this has happened. The rubber insulator on the top side would look compressed as normal but this compression would be from the downward push on the shock by the coil spring.
Like I said this is only my speculation and I hope to find out for sure.
The fact that the shock shaft is not properly retained would not become apparent until the unit is installed and the weight of the truck is put on the unit to compress the spring at which time the shock upper rubber insulator would be able to decompress and the shock shaft would be able to extend upward from the mount.
No one else has responded to having the same circumstance with the shock shaft extending from the upper mount so this may not be wide spread.
I don't know what else might cause the clunk but my clunk is no longer there.

 

[WTERUNNER]

I have not bothered to say what I think the issue was even with my engineering and automation background because it would only be speculation without being able to see the disassembled components myself.
I don't think the issue is with the shock internally.
I think the problem was central to the rubber insulator bushing and backup washer that is on the bottom side of the upper spring mount. The bushing and washer fit inside a recessed pocket in the upper spring mount and can't be see after the unit is assembled. After thinking about how the assembly process in undertaken I think that IF the backup washer becomes misaligned on the shock shaft as the top compression nut is tightened, the washer could catch on the side of the recess as it is pulled into the recess. This could cause the washer to be deformed and damaged to the point that it does not back up and compress the rubber bushing on the bottom side of the mount as it should. Since it is pulled into the recess and would be hidden by the rubber bellows around the shock shaft the assembler would not know this has happened. The rubber insulator on the top side would look compressed as normal but this compression would be from the downward push on the shock by the coil spring.
Like I said this is only my speculation and I hope to find out for sure.
The fact that the shock shaft is not properly retained would not become apparent until the unit is installed and the weight of the truck is put on the unit to compress the spring at which time the shock upper rubber insulator would be able to decompress and the shock shaft would be able to extend upward from the mount.
No one else has responded to having the same circumstance with the shock shaft extending from the upper mount so this may not be wide spread.
I don't know what else might cause the clunk but my clunk is no longer there.

Good to know, Thanks! Hopefully when I get my TRD PRO kit installed I won't have any issues but if I do I know exactly what to tell them.

 

[joshoowa]

I'm starting to experience a subtle clunk noise too when I go uneven roads. It sounds like a metal hollow clunk noise, similar to like a strut bolt not being tighten. Only uneven, if I go over something leveled no noise. Leads me to think it coudl be something with the sway bars?

 

[DRDpro]

White Brick,

Thank you for keeping this thread alive with your recent experience.

I haven’t been driving mine very much but took it out the other day and clunk is still there.

Summer heat, both sides still cllunking

Both rubber bushings above the metal top shock mount and they seem to be tight (can’t rotate them by hand)

Also noticed a thin rubber bushing where the top of the spring meets the bottom of the top shock mount and from what I can tell looks normal.

Will have to take a closer look when I get a minute.

 

[kzanard]

Cooler weather is back, so is the clunk

I almost forgot how annoying it was as it was just about non-existent during the summer months. With these cool nights and mornings the clunk is back in full effect. Does anyone have any new updates on solutions?

I mentioned it on my 5K and 10K services so it would be in my records, but the dealer still found nothing. I am hoping some of the other dealers are more knowledgeable than mine!

 

[Bevo]

It's still hotter than two rats f***ing in a wool sock down here, so I am clunk free.