Clunk/Creak after lift install...help

SOLVED!

I'm very happy to report that I've solved BOTH the Clunk and the Creak! I'll post what I did incase others with the same problem stumble upon this thread.

So, I got rid of the "clunk" with a sway bar relocating bracket from Toytec. The spring perch was hitting the sway bar. Then I still had a creaking noise when the suspension would compress. I took both asides apart and reorientated both springs around to face in the direction the FSM indicates (both bottom coil ends facing back and to the left a little). I also bought some 1/16" thick PVC rubber (shower floor lining material from Home Depot) and cut out gaskets to go on the driver's side both above and below the 1/4" taco lean spacer and above the top hat on the passenger's side. While I was at it, I also cut out a gasket for each spring perch and placed them between the bottom of the spring and the perch. Lastly, I put a bit of silicon grease on both top hat gaskets to ensure the spring nestled into them correctly. Put it all together and all is good. No sounds whatsoever!

I'm not sure what it was that did the trick but I took every precaution and it worked.

Thanks to everyone who helped me out. You guys are great!

 

I am having ALMOST the exact same problem. I have a 2013 Double Cab Limited 4WD. Here is what I installed:

OME 885 Springs with all new hardware (coil perches, top plates, isolators and 1/4" DS spacer.
Bilstein 5100 shocks (front and rear).
Icon 3 leaf progressive AALs.
I also installed new greasable Moog tie rod end links and sway bar end links.
I sprayed the heck out of all the front parts with some Teflon spray and cleaned all of the leaf springs with denatured alcohol and sprayed each leaf with dry graphite lube. I also drilled out each leaf on the AALs and installed anti-friction pads on the end of each leaf.
The leaf springs are absolutely silent. I get a definite "clunk" when I go over a bump which I expect is the sway bar because it is VERY close to the coil perch. I also get a "rattling" noise from the front end that seems to be there almost all of the time. I read about the 1/4" spacer being a suspect, but if the three bolts for the top plate are tight, how can the spacer "rattle? I did check all of the bolts/nuts and other hardware that were removed for the install and everything was good.
So, I am planning on installing the sway bar relocation kit, but cannot figure out the rattle. Does anyone have any other ideas? Any help/advice is MUCH appreciated.
Thanks,
Ken

 

Yes, install the relocation bracket, then check if both tops of the coils are sitting up into the top hat gasket thing. I bet if you remove the coils, you'll find scuffing on the top hats where the spring has been hitting the metal. It's very easy to pinch the gasket in the center and push it up instead of fitting properly. I found a little silicone grease helped them seat right. Also make sure both bottom coil ends are sitting facing back and to the left a bit as per the FSM.

 

Thanks Cperalta. I am not clear on the part you are talking about though. Between the top of the spring, there is a coil isolator made of polyurethane, then the top plate sits on that. I am not sure where there could be any metal on metal contact except for the top plate and the upper shock mount. Is that where you are talking about? It seems like if the three top plate bolts are tight that there would be not room for movement, right?
Also, the "rattling" noise that I get almost sounds like the 1/4" "Tacoma Lean" spacer rattling, but again I don't know how this could be possible with the three top plate bolts torqued down.
Thanks again for the help, I am just kind of baffled.
Ken

 

The metal on metal I'm talking about would be the inside of the top coil against the outer edge of the little lip that hangs down from the top hat (you may not have noticed that the metal actually extends down a bit). If you don't pay close attention to how you sit the top of the coil on thar isolator, you can push the inside part (rubber) up with the coil and create a situation where the coil makes contact with that metal lip of the top hat. If you pull your top hat and the isolator off and hold them in your hand, you'll see what I'm talking about. And while you've got it apart, put some gasket material above and below that taco lean spacer just to take it out of the equation.

 

OK, I think I know what you are talking about now. Thanks for clarifying that for me. Sometimes I am a little slow
I ordered the sway bar relocation kit and also a set of Energy Suspension sway bar bushings with greasable mounts. I got the bushings today and am just waiting for the relocation kit. I will install that first and see what happens. I really dread taking the coil assembly apart again, but if that is what it takes.
Funny thing though, I drove the truck today and I definitely hear two separate sounds: the one is the "clunking" when I go over a bump, but the other is a more constant "rattling" sounds like something is loose, almost like shaking a spray paint can but a little deeper sound. Does that still sound like the spacer problem?
Thanks again for all the help. The truck rides GREAT but this noise is driving me crazy!
Ken

 

The clunk is most probably the sway bar. Feel the sway bar with your finger where it's closest to the coil perch. It should be perfectly smooth, if not, it's hitting. As for the rattle, I had more of a creaking sound like an old mattress. I'm not sure what your rattle could be but focus on one noise at a time (sway bar first).

And don't listen to those who say it just needs to "break-in" or that it'll go away. Stick with it and you'll find and fix it.

 

Thanks CPeralta, I agree and think that is great advice. I did feel down by the sway bar and could not tell if there was any evidence of contact, but they are SO close that I am 99% positive that you are right about the sway bar making the clunking noise.
I am going to do as you suggested and fix the sway bar issue first and then worry about the other noise, unless I see something obvious in the mean time.
Thanks again to everyone for the help. REALLY appreciate it!
Ken