Front end "klunk" and "bang" after lift and new shocks. PLEASE HELP!!!

2002 Tacoma 4wd double cab SR5 6 lug.
I installed Bilstein HD shocks and struts, new coil springs, and a Daystar leveling kit 1.5" add a leaf rear and 2.5" front. I had to drive the truck for a few days before an alignment. during that time i noticed my front end was making a lot of noise that wasn't there before.
driving on smooth pavement is great, but a soon as i hit any bump the front end sounds like absolute HELL! I got an alignment and nothing changed, I told the mechanic about the sounds and he said all the alignment parts were fine.
I am concerned that the front end lift (polyurethane above strut spacer) is putting too much pressure on the suspension parts. I was thinking of removing the spacers and cutting them in half in order to lower the front an inch or so and take some of the pressure off.
I read an article that said any lift for tacoma over 1.5 in front requires a differential drop and a few other parts to avoid damage.
I almost don't want to drive it because it sounds so rough. It is my daily driver and i'm hoping lowering the front a bit may solve the problem.

Any good ideas or advice will be very appreciated.
What is causing the noise? How do I fix it? ETC..?

 

What exactly do you have in the front?

Are you saying.....You have 2.5" front spacer? Is that the total thickness or the lift amount? Where is this spacer? Inside the coil assembly? Or is it ontop and outside of the coil assembly? Your new coils - are they stock?

My first thought is... Take a look at your steering knuckle. How much clearance is there between the knuckle and the coil?

 

The spacer measures 1.5" thick to produce a 2.5" lift. The spacer sits above and outside the coil assembly, not in the coil. The coils are moog and to factory spec.
The knuckle looks to be about 2" from the coil.
Ill try to post a pic when its light out.

 

I also noticed the " klunk" is loudest at about 10-15 mph over lightly bumpy road.

 

spacers mounted atop the CO are bad news...
messes up the factory engineered suspension geometry.

as far as the clunk...
is the lower portion of the CO hitting the CV axle ?

Often the lower eye of the CO is spaced forward some.
there are usually alignment spacers that do that.
Long side of the spacer is to the rear, pushing that forward some.

 

You have a sway bar? Try removing the endlinks and go for a cruise.

 

I'm thinking about remove the spacers and replace what i have with a quick lift strut assembly. I want the front to be lifted 1.5"-1.75" above stock. I've looked but am having difficulty finding them for sale. any suggestions? if anyone knows where to find them please let me know

 

Why has no-one mentioned getting the lower control arms torqued? 9/10 allignmnet shops dont tighten down those nuts to the proper torque (I believe 100#s) and you'll get some loud pops from stuff shifting around. IF everything else looks good, thats my bet.

 

lower control arm torque you say? I had it aligned yesterday so I'll call and ask if they did that.

thanks for the tip.

 

I would recheck the swaybar bushing since you've done an alignment.

 

check the sway bar bushing? this may be a dumb question. but, what am i be looking for? to see if its pushed out of place?

 

I just talked to the alignment guy.
He said he adjusted the 4 cams on the lower control arm and adjusted the toe ends. not sure what you mean by "torque" lower control arms. Is that something different?

 

He loosened the lower control arm nuts to adjust your caster/camber. They need to be tightened to a certain number of foot pounds in order for parts not to shift around and make a clanking noise aka torquing them down. The torque number is somewhere between 100-110 pounds. I cant remember the exact number. Let me do some searching on this.

 

post number 4. Its 100#s
https://www.tacomaworld.com/threads/front-popping-after-alignment-pot-hole.259828/

 

The spacers are not the problem, I have spacers and no klunks. Something is either loose or worn out or installed wrong. Post some pics from a few different angles of the front susp. And maybe someone will spot somethin.

 

UCA hitting the coil at full droop?



does it only happen when your suspension is topped out? Ie: right after you hit a speed bump?

 

I've heard plenty of times of the sway bar making noise after a lift is installed. It may be banging off the spindle a little.

 

Either the bushing are worn out or like said above, at full compression sway bar hitting the coils.

 

Nut and bolt check! Make sure everything is tight!

 

As far as sway bar making contact with the spindle, what spindle are you referring to?

All great suggestions, thank you. I'll dive into it this weekend.

I'll post what I find and try to include photos