Clunking front end noise. (Resolved)

I have a 22 Trd pro and I did the Westcott lift on it. After the alignment I started having a reproducible but inconsistent clunk / pop. It felt like a Spring was popping Into place. I could feel it in the brake pedal and a little in the steering wheel. Figuring, I just finished a lift and the alignment I went and retorqued every bolt. It mostly made a noise when I was turning and braking and yesterday it made the noise when I put one wheel up on the curb to hop it. No brakes and i was not turning so with that data my mind went spinning as to what it could be. Well with me under the truck and the wife trying to reproduce it in the driveway. I narrowed it down to what I thought was a front diff. As I was under the truck and the wife was in the truck, she started searching the net and came up with a possible solution. She found it on the 2.5 gen page. The TRD skid plate was put on too tight and as the frame flexed from braking or twisting it was causing it to unbind and shift making a piping /clunk noise. Sure enough that was it. I had the bolts too tight when I did the cat shield. I put a thin sheet of high density rubber between the skid plate in the frame and all is well now. The wife saved the day.

 

My truck developed a similar noise after the 10k mi service. I brought it back and the dealership confirmed the noise coming from the front skid plate. Apparently they can/will remove it for inspections? Anyways, guessing they used a torque gun to reinstall as a shortcut.

Dealer ordered all new bolts and washers, will install when they get them.

 

Many stories of overly tight skid plates causing weird noises. Clearly techs don't follow torque specs and just make shit TIGHT.

 

Just confirming here that after backing out the skid plate bolts and re-torqued the skid plate to spec this noise has not reoccurred.

 

Anyone know what the OEM torque spec is for the skid plate?

 

if your a dealer tech, wide open impact wrench to max , lol

 

29Nm

 

Where did you get the high density rubber from? I have been told also that POM washer could work and I saw them in many places. I have TRD skid plate and miller cat shield so rear bolts of the skid plate also hold the cat shield in place using the security bolts from miller cat. They have lower torque spec (15N-m) and when I torqued it all to spec, noise reduced drastically, but not completely. I hear it on extreme turn positions when moving around at low speeds. Tx

 

Same issue, sounds violent. Have about 3200 miles on my 23. After the lift I just zinged those skid plates bolts on. I am going to investigate tomorrow, glad I found this thread. Thanks, I'll report back.

 

Lowered to factory torque specs, still a little clunk. What exactly did you use to fix the issue? I was thinking nylon washers between the plate and frame?

 

I just wanted to say thanks for this thread this was my clunk problem too! I assumed it was a suspension problem from my lift so I’m happy

 

I’m happy to see I’m not the only one I’ve been having this same problem! I took it to the dealership they told me my bolts were loose on my skid plate and said they torqued them down to the correct spec tops me they test drove it and not making the noise anymore I pick my truck up today and the first somewhat tight turn in a parking lot and it started again just with the slightest turn of the wheel it makes that noise have any of you got it to go away for good?

 

Alright well I loosened and re torqued bolts noise was still happening went and got 1/8” nylon spacers and noise is completely gone hope this helps someone else who has this problem!