Clunk and Rattle in Front End Over Bumps

I had a clunk everytime I went over a speed bump. First dealer charged me $100 to tell me it was the rock sliders. It wasn't.
Second dealer charged me $150 to tell me it was because the factory said plate was dented. Didn't fix it.
I upgraded to Bilstein 6112's and the noise is completely gone.

 

I wrote the service manager with the issues and politely described everything without accusations or complaints.
I linked that 4Runner TSB as reference and also attached a short video of the noise on YouTube from another Pro owner.
He was very nice about it all and got back to me to see what I'd like to do about it and what I thought the issue may be.

As of this morning he has ordered new Fox front strut assemblies and they should be in next week or so. The work has been pre-approved under my Platinum Toyota VSA warranty per his email.
Truck is technically a few weeks out of it's 3 year factory warranty, but covered until 2030 under the VSA I bought with the truck.

I'll let you know how it goes after the repairs. I hope this is the fix.

 

Very interesting subject. I hear a noise on the front end of my Sport but it's not a "clunking" sound. Just the sound of all the suspension components doing their job.

 

This is what that noise sounds like in the cab from another Pro. You'll hear it twice in this short video.

https://www.youtube.com/shorts/h4H9JZzjjoI

 

The truck went in today since the parts arrived.

They had it for about 3.5 hours.

Replacement of both front struts and an alignment under warranty.

As of right now it's dead silent in the front end, rattle is gone completely, not even a hint of it. It also doesn't feel as 'loose' when you hit bumps anymore.

The struts look a tad updated to me. Still the red springs and fox shocks but there are minor differences in the spring perch on the shock and the springs aren't marked with a black splotch and white splotch for left and right sides like they did from the factory.
Instead they have a nice stamped TRD logo on the red spring and some very small writing next to it I couldn't make out but will check later to see exactly what it says.

The part numbers on the service order are stock though, PTR61-35170-RF and PTR61-35170-LF for left and right front.

Hopefully when it gets bitter cold again the rattle doesn't return. It is 35 degrees today, and it was still doing plenty of rattling on the way to the dealer.

Hope this helps anyone with a similar front end rattle.

 

This same rattle just started in my 2019 Pro with 40k miles. The weather also got cold. I don't have the extended warranty - not sure what will happen if I take it in.

 

I'm having the same problem with my 2021 TRD Pro. There is a low-pitched rattle in the front particularly at low speeds and when I go over small bumps. Even backing out of the driveway causes it to rattle a little bit.

I'm curious to know if the new struts are still working out for you. I've got about 23,000 mi on my 2021 so I'm not sure if I'm still within the warranty or not. I totally did not expect this to happen at 20k miles on a $53,000 truck.

 

Good to hear you have gotten it sorted……sucks that you had to educate the service manager

 

Just wanted to follow up on this. I took my truck to the local Toyota dealership today and they said both front struts are bad and are replacing them under warranty. 2021 Tacoma TRD Pro with 25,000mi.

 

I’ve had a squeak in my front end too. Took the skid plate and bolts off- still squeaked. Thought it might be the Heim sway bar links I installed. Ensured everything was tight- still squeaked. Purchased the longer lower strut bolts from the 4Runner but haven’t yet installed them. Read about how some low mileage Fox struts were replaced by Toyota so I have an appointment to go see them. I’m at 37k miles. Also read some low mileage Tacos had bad front body mounts. I was going to have them check that too.

I found MY culprit. The two north to south brackets that hold the skid plate. The bolts were a little loose, snugged them up, and VOIL’A. Fixed. The truck feels new again. I can’t believe that is what it was.

 

that's great to hear, and thanks for posting your solution. these squeaks and rattles can really get you down. everything else on my truck works just fine, but this front end rattle makes me dislike the whole truck on some days!

 

Were you able to fix it? The same thing happened to me, I changed all frame mounts, the sound was still there, but I didn't give up, and I found that the problem was coming from the sunroof

 

My skid plate wasn’t loose either but, unlike you, I kicked it in several places with my slipper so, I don’t know if that matters. But in all seriousness, we found the frame member the plate is bolted to was actually the culprit. Might want to remove it and check those cross members the plate gets bolted to.

 

Complete and Utter BS that ^.
The fox shocks are dead silent even when taken to extremes. I've been impressed with them as OEM level grade.

It makes no sense whatsoever that off road intended shocks would be caused to rattle with a small bump. I am amazed at the things people are willing to say with a straight face these days...

Great news that they sorted it out for you.