2004 Tacoma front end knock, need help tracking down the cause

[DaveM]

Having some issues with my Tacoma front end. I posted this to the TTORA forum but haven't had any replies yet. I know there's a lot of Tacos in the membership here so hoping someone will have some suggestions for tracking down this problem:

The truck is a 2004 4x4 4dr Tacoma. About 160k miles. No mods other than upsized tires (31" BFG AT/KO) and a modest 1.5" - 2" lift via shackles and adjustable Bilstein 5100's.

The symptoms: when going over a speed bump, or into a dip at between 5 - 15 mph (anything that lifts the front end a bit then quickly compresses it) result in a noticeable metal knock in front end. I can't fully raise the truck to really pull on the steering rods, sway bar or anything else at home but have had my shop look twice with truck on the lift. Both times they said it all seemed tight, nothing looked worn or busted and nothing clicked or moved when they tugged on it. But the knock persists. It's been there for about a year or more but I can't see anything that would be causing it. Hoping the fact that it only happens on a quick compression of the front end after a bump or dip might be a clue as to where to look.

Would love some help determining what to look at next.

Cheers,
David

 

[smokeysevin]

If you have stock upper control arms they might be contacting the coil spring on droop. My tundra did that when I had a daystar kit on the front but I don't remember my 5100's doing it.

Sean

 

[bkg]

If you have stock upper control arms they might be contacting the coil spring on droop. My tundra did that when I had a daystar kit on the front but I don't remember my 5100's doing it.

Sean

this was my first thought as well.

 

[DaveM]

All stock except for the Bilsteins. Including the spring itself which was transferred from the OEM shocks. I think these are around 5 years old, but the noise only started a year or so ago. I'm thinking something has worn or loosened instead. TTORA member has suggested the top shock bushing may be loose or worn. I've inspected them and they seems tight but I can't tell with the truck sitting on them! I'm replacing the front shocks anyway so maybe I just need to have the bushings done as well and hope that's the issue.

What I'm really trying to figure out is if this sound might indicate a problem with the CV joint or wheel bearings. I'm hoping not.

 

[Kpack]

Also check out your lower shock mounting bolt when you are in there. Recently my rear suspension was making a knocking noise and it turned out that the "OEM" bolts were the wrong size or they had worn down a lot. Correct sized bolts solved that noise for me.

 

[DaveM]

I'll see if I can grab an iPhone recording of the knock as I back out of the driveway. It's the only place I can reliably recreate the sound.

 

[roving1]

My rubber coil isolator is shot. When I go over speed bumps I get a clunk. Also sometimes when I am steering quickly at low speeds. Also pulling slightly towards that side. Lift and all new suspension stuff soon so I'm just letting it be for now.

 

[DaveM]

Posted a quick iPhone recording on Box. Hopefully this will play for you. Funny thing, this morning the "knock" sounded more like a worn busing sound for the first time, possibly due to the colder weather past few days. Normally more of a single thump or clank from front. Beginning to think this will definitely all go away as soon as I swap the shocks and bushings.

https://stanford.box.com/s/kjo40pz2rmvyklhklr621e9uac2dwyi8

 

[surlydiesel]

Sway bar links...

 

[longtrail]

2nd on sway bar end links. My '02 tacoma had a similar knock/clunk at low speed bumps that took me forever to locate.

 

[DaveM]

Turned out to be the pad or rubber spacer at the top of the strut. It was deformed and out of place, pushed into the space above it. From a hard knock on the trail I guess. When I had the new struts put in they re set the spacer and everything is fine now.