Replacing Front Diff Mount Bushings (w/ parts)

UPDATE: I ordered the parts and will report fitment when they arrive. The individual part number for our 3GEN assembly is 52380-04071, but all links reference back to the 52380-04061 which is for 2GENs. Fingers crossed.

I have a clunk up front that I think is coming from the front differential mounts. Upon visual inspection, they are toast. After looking for replacement bushings, most queries led to full replacement of the Toyota Tacoma SUPPORT ASSEMBLY, FRONT DIFFERENTIAL - 5238004071 at ~$140 x2.

After finding this post from @Plastics Guy who is making them for 1GENs (video), I began to compare part numbers. Someone please check my logic, but according to this diagram I think it's possible to replace just the bushings with part #s 41653B (x2) and 41654A (x2) for about $50 instead of replacing both complete arms 5238D (LH) and 5238D (RH) for $300.

FULL PARTS LISTING




Looking at the diagram, it appears that circle parts will work since above SUPPORT ASSEMBLY is good for years 2005-Present.

 

I also have a clunk up front that I can’t seem to find. What made you think it was the diff mounts? I will have to take a look at mine now to see if mine are shot. I have looked at everything or atleast I thought. And I have retorqed everything also.

 

Process of elimination. I’m on FOX 2.5s and the ride is great. I’ve had a weird clunk but only on small square edge bumps. It’s become progressively worse over the last few months.

It kind of sounds like a ball joint or a lower shock mount, but I know it’s not.
- Alignment is perfect.
- Torque on lower cam bolts is good.
- Control arms torqued and greased.
- I don’t have a sway bar
- Suspension has plenty of down travel

Tonight, I removed the skid plate to change the oil and noticed that the bushings are shot. I have a factory installed diff drop that I’m going to remove and replace the bushings while I’m in there. Hopefully this will fix the issue.

 

I appreciate the input. I’m on Toytec 2.5s and I also get that clunk on square bumps(deep man hole covers). I will definitely check my bushings this weekend. I’ve also found out that it is worse in the cold. Let me know what you find out and if you can, take pictures. Thanks

 

I just noticed that the passenger radiator bushing is smoked too. I’ll replace these too. Here is a thread for referenced noises (search word = toast)
https://www.tacomaworld.com/threads/pelfreybilt-vs-demello-bumper.412462/page-5#post-11692336

 

Did you get the noise to stop? So it has been warm here in NC today and I have zero clunks even on the same bumps I hit every day. So I assume it has to be one of the bushings that shrinks when it is cold and expands under higher temps. What do you think?

 

Are you guys positive it’s coming from the front. I get a clunk occasionally, but have absolutely confirmed it’s the passenger rear Dakar leafs smacking on the metal shackles where the military wrap occurs.

It only happens “sometimes” while turning over small bumps or potholes

 

Definitely happens in the front.

 

I also have the Toytec with drop down diff and upper control arm conversion. small cracks and train tracks always made a "loose" clunk noise in the front. I have tried to check and torque all nuts and bolt which got me no where. I usually can find the problem in suspension issues but have not so far. I am at a loss. Could be because I am at max recommenced height. Dunt know.

 

Do you have this issue more when it is cold outside or is it all the time? I’ve come to the conclusion that it has to be a bushing somewhere. I just need to find out which one.

 

Could be cold weather. But the stock radiator bushings and diff bushings are crap.

Positive my clunk is coming from the front. I can move the radiator mount by hand and can see the bushings on the diff rotted.

Sounds like you are topping your suspension on and running out of down travel. 1/2” can make all the difference in the world.

 

Diff drops are unnecessary and can cause more harm than good on the 3rd gens

I had one and fortunately some guys on here expressed the same. After I took it out, my angles were the same...something to think about

 

I don't think its a lack of down travel as I have no noise on bigger bumps. It articulates good in both directions. Cold or warm, Its consistent.

 

If you’re replacing them with Toyota OEM they may be the exact same ones you have and will go bad just as fast again. Something to think about.

I’m thinking maybe Energy Systems make an aftermarket version of the bushings?

 

It’s coming out when the new bushings arrive.

 

Hey go2 sorry to burst your bubble but I don't think these are the parts you need. I'm trying to track down the rubber bushing after tearing mine when I got yanked out of the snow on the weekend. I ordered 41654-04020 and 41653-04020 from toyota, they're 41653B and 41654A in your diagram. After getting the parts and pulling off my mount arm I've found out a few things. 41654-04020 is just a glorified penny washer and 41653-04020 is not damaged on mine. It's like a big washer with some rubber bonded to it but really doesn't take the load of the diff. It looks like I might have to buy the whole arm to get the bushing I'm after. I've got a photo of all the parts but i'm having trouble posting it.

Also as far as sources of noise from up front I found that the diameter of the bolts and spacers in my diff drop kit (can't remember if its toytec or revtek right now, will confirm later) are smaller than the diameter of the mount bushing and hole in the cross member so it's possible that the whole assembly is moving around for some of you, but I don't see any evidence of that on mine. I'll likely find the correct size bolt and drill out my spacer in the future to prevent that possibility though.

 

Here it is apart

 

Thanks for the info. I’m pulling mine this weekend.

 

How did it go?

 

does part number 4165404020 (plate) have rubber on the bottom? or is it just a washer?