Unique Suspension Clunk w/Video... Looking for Solutions

T

Terra Firma

New member
Hello all, I have had a unique sounding clunk from the front drivers side. I posted a diagnostics video a while back that received some feedback (in the wrong thread) and had a few reach out with similar noises with no solutions through their own problem solving. 10K miles currently, lift installed at 4K. Noise has been unchanged since first appearing at 5K miles. Toyota "Can't hear it".

A few of the things I have done below:
- Had the cam bolts backed out and re-torqued to 129ft/lbs.
- No contact of sway bar on skids
- No coil contact on KDSS lines
- No play in lower or upper bushings
- No leakage along KDSS lines/at pistons
- No KDSS play, warning lights, and fully functional at speed
- No noise when vehicle rocked side to side when in park.
- All bolts torqued to spec, bushings in good shape
- Noise appeared within a month of lifting

Vehicle Details: 2016 TEP with KDSS, Icon stage 2, TRDP wheels, RCI skids, 255/80/17's.

Video: https://www.youtube.com/watch?v=WKlZBSDr5jc
As you can hear, apart from the locusts, the noise occurs on both up and down travels, and inconsistently through travel and speeds (start-stop, speed, and one curb).

Any insight or other ideas would be awesome! :cheers:
 
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I had a weird clunk. It ended up being a drive shaft that needed lubrication. Every oil change I have my tech put a little grease in the ol' zerk. Clunk has never returned. By lifting your ride, you may have changed the angle of the drive shaft a few degrees. It's worth the free grease.
Good luck buddy. These kind of tuning projects suck.
 
I too have the same clunk. Took it to the dealer and they said they don't know where it's coming from. I'll definitely try everything at this point.


Sent from my iPhone using Tapatalk
 
I would start by removing all skid plates.

Several points where my skid plates connect to the frame and to each other have rubber grommets between them to allow some flex and get rid of many random noises I have encountered.
 
Wow
Watched the video about 100 times and can't really tell it's hard to disg without being there.
Have you tried jumping up and down on your bumper while someone lays underneath see if it makes the noise. ?
I'm thinking it's definitely a suspension issue but idk I could be wrong. Maybe an UCA?
I'd just try jouncing the suspension with someone to help listen for the noise.
I'm sure you've done this already but try redoing the lift/ going through every nut and bolt that was removed or touched just for process of elimination. Instead of looking at other places look at what you touched last especially is you had more than just yourself working on the truck.
 
Wingman707 said:
I had a weird clunk. It ended up being a drive shaft that needed lubrication. Every oil change I have my tech put a little grease in the ol' zerk. Clunk has never returned. By lifting your ride, you may have changed the angle of the drive shaft a few degrees. It's worth the free grease.
Good luck buddy. These kind of tuning projects suck.
Click to expand...

Greased after reading your reply and I'll find out today if that did it, thanks!
Jeremy556 said:
I would start by removing all skid plates.

Several points where my skid plates connect to the frame and to each other have rubber grommets between them to allow some flex and get rid of many random noises I have encountered.
Click to expand...

Good idea, no room for play without some sort of slippage. I will get some grommets and space out the skids.

MarkamisPrime said:
Wow
Watched the video about 100 times and can't really tell it's hard to disg without being there.
Have you tried jumping up and down on your bumper while someone lays underneath see if it makes the noise. ?
I'm thinking it's definitely a suspension issue but idk I could be wrong. Maybe an UCA?
I'd just try jouncing the suspension with someone to help listen for the noise.
I'm sure you've done this already but try redoing the lift/ going through every nut and bolt that was removed or touched just for process of elimination. Instead of looking at other places look at what you touched last especially is you had more than just yourself working on the truck.
Click to expand...

I appreciate the feedback. In this case all bolts tight and it does not make the noise when the car is rocked or jounced. Even had two big dudes rock the car by standing on sliders. No noises at all. Edited the details above.
GzTEP said:
Check nitrogen pressure in coilovers
Click to expand...

Is this something an off road shop can do without losing any pressure?
 
Terra Firma said:
Hello all, I have had a unique sounding clunk from the front drivers side. I posted a diagnostics video a while back that received some feedback (in the wrong thread) and had a few reach out with similar noises with no solutions through their own problem solving. 10K miles currently, lift installed at 4K. Noise has been unchanged since first appearing at 5K miles. Toyota "Can't hear it".

A few of the things I have done below:
- Had the cam bolts backed out and re-torqued to 129ft/lbs.
- No contact of sway bar on skids
- No coil contact on KDSS lines
- No play in lower or upper bushings
- No leakage along KDSS lines/at pistons
- No KDSS play, warning lights, and fully functional at speed
- No noise when vehicle rocked side to side when in park.
- All bolts torqued to spec, bushings in good shape
- Noise appeared within a month of lifting

Vehicle Details: 2016 TEP with KDSS, Icon stage 2, TRDP wheels, RCI skids, 255/80/17's.

Video: https://www.youtube.com/watch?v=WKlZBSDr5jc
As you can hear, apart from the locusts, the noise occurs on both up and down travels, and inconsistently through travel and speeds (start-stop, speed, and one curb).

Any insight or other ideas would be awesome! :cheers:
Click to expand...

Noticed you listed Icon as the manufacture, had this issue in my FJ Cruiser, actually ended up being the springs not properly seating, ICON had to warranty this issue twice for me. Good luck on the fix
 
try getting the 4runner on a jack stand on that side. Jack up the tire up all the way and then let it extend all the way down, see if you can replicate the noise that way? It sounds like something is binding. That sound would drive me nuts.
 
I've successfully diagnosed suspension clunks/rattles the following way on my past Jeeps:

You can usually replicate the sound with the vehicle at a standstill by either pushing it side to side, have someone bounce/push down on the front/rear bumper, etc - whatever motion tends to produce the sound. Have a buddy do this and slide under the vehicle to not only listen, but more importantly feel for it. I can specifically remember two times in the past when I could hear the popping/clunking inside and outside of the vehicle but could not identify it until I place my hand on the culprit and felt the vibration/pop effect caused by loose suspension part.
 
I've had this problem for while now. I've postponed my lift due this. Dealer greased and oiled the bushings connected to the KDSS. It disappeared for a month. Next step is to replace the bushings.
 
I appreciate the responses. ICON confirmed that low nitrogen charge (idea from above) could cause a clunk of this nature, though I am unable to locate any type of shop in Omaha that has the ability to charge/check nitrogen shock pressures, especially up to 250 PSI. Non-resi shocks like these do not use the schrader valve, but a needle through a rubber diaphragm, further complicating the

Anyone know of any shops in the mid west/Colorado area that has this capability? Units are under warranty (started at one month after install) but the truck is daily driven and not having a vehicle for 2 weeks is not an option.
 
Terra Firma said:
I appreciate the responses. ICON confirmed that low nitrogen charge (idea from above) could cause a clunk of this nature, though I am unable to locate any type of shop in Omaha that has the ability to charge/check nitrogen shock pressures, especially up to 250 PSI. Non-resi shocks like these do not use the schrader valve, but a needle through a rubber diaphragm, further complicating the

Anyone know of any shops in the mid west/Colorado area that has this capability? Units are under warranty (started at one month after install) but the truck is daily driven and not having a vehicle for 2 weeks is not an option.
Click to expand...

Really doubt it is the coil overs... They are of pretty good quality control.... I would start by taking those skids off the control arms. They are useless and a source of noise IMHO. In fact. just take off all your skids just to troubleshoot.....

Also... don't ignore the rear. I've had many noises sound in the front, but the source of the issue is in the rear. It will travel right through the frame.

It's an interesting video to see KDSS in action from that view. Almost looks to me like the cylinder is moving way too much for the speeds you are going, but I have nothing to compare it against (just a guess). I would think it should be locked in place pretty much once you are moving above a few mph..
 
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wfo9 said:
Really doubt it is the coil overs... They are of pretty good quality control.... I would start by taking those skids off the control arms. They are useless and a source of noise IMHO. In fact. just take off all your skids just to troubleshoot.....

Also... don't ignore the rear. I've had many noises sound in the front, but the source of the issue is in the rear. It will travel right through the frame.

It's an interesting video to see KDSS in action from that view. Almost looks to me like the cylinder is moving way too much for the speeds you are going, but I have nothing to compare it against (just a guess). I would think it should be locked in place pretty much once you are moving above a few mph..
Click to expand...

Next step is to take off the skids and put some rubber bits in between them like a previous poster suggested and you are seconding. I have taken off those LCA skids and the sound is the same. Those skids also already saved me from a nice sharp rock when I slid a ways to the side and off the rock at Kansas Rocks, paid for themselves already!

I found it very neat to see the KDSS work as well. Most of the video except for the last part is all below 13mph so it makes sense that it is cycling, then firming up at speed(latter part) .

I will try to get the time to take all skids off and go pro the rear axle this week, then post back results.
 
Didn't some people think it was the LCA?

FWIW, I seem to have the same sounding clunk, haven't figured out what it is yet though.
 
Update:

Went by the local Omaha Ducati dealership who had the needle and gauge to check the front left coil-over.... right at 250PSI. Was hoping it was low to put an end to this madness.

Removed skids and drove around, still there. Added rubber strips around the bolts between skids as an idea from previous poster.

Go-Pro tonight showed that the noise is definitely coming from Front Left side, as I put the Go Pro around all sides and the noise was barely audible anywhere else.

Any other thoughts folks?

spencenasty said:
Didn't some people think it was the LCA?

FWIW, I seem to have the same sounding clunk, haven't figured out what it is yet though.
Click to expand...

Yes, and I had the bolts backed out then re-torqued and checked for play in the bushing itself. Doesn't mean this isn't it but it is less likely.

Tomorrow I will back off the UCA bolts torque wise, drive a short distance (I have a 200yd loop that it makes the clunk on) and regrease/torque to see if that does it.

I am really running out of ideas short of switching out the shocks for OEM, which I may try this weekend at last resort.
 
Ended up being my lower control arm. Had an alignment done on Friday. I even mentioned to the tech about making sure they were torqued correctly. Owell. I tightend today. Nice and quiet. Amazing the racket/clunk something so minor can produce.
 
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