Front end clunk/creak near cross member in front end

I have an 06 tacoma trd with 170,000 kms on it and recently have had a clunk/squeak noise coming from the front end when braking quickly and going over bumps and is quite loud when on a bumpy road like a fsr. I've read all I can on the forums on fixes for this but still have not found the problem. I tried myself to find the problem based on the suggested fixes I found on the forums with no luck. I then took it into a mechanic shop that works on lots of offroad rigs. A quick diagnosis looked like the driver inner tie rod; however, this did not fix the noise. I took the truck back to look at it again at the shop and we were able to create the sound in the shop by jacking up the front end. They tightened every bolt in the front end and repeated the sound with no luck. The sound would come from one side and then the next time the other side in the front end. Could really feel the creak when you held onto the cross member that is connected to the frame in the front end when you lower and drop the truck. Again, tightened all the bolts and still not sure. Please let me know if you have any suggestions. It's driving me nuts!

What it sounds like:
- It is a clunking noise that sounds like metal on metal but not a deep clunk almost like its thinner metal making the noise.

When it happens:
- Backing up with wheels at 3/4 lock slowly. Also happens after when going forward.
- Jacking up front end clunk/creak happens when the wheels are just about off the ground. Sound happens again once the truck is dropped back down and then pushed down on the bumper.

Thoughts:
- Feel it in the cross member, mechanic thinks it has something to do with the bending of the frame once the load is taken off the wheels. Almost sounds as if it's friction creaking like in a cracked weld. The welds on the cross member all look fine.

 

Anyone have any ideas? Losing my mind here, read everything I can and still nothing.

 

Have you checked the lower strut bushings and swaybar end links? Also check the cab, engine and transmission mounts. Transfer case has no mounts just like a 1st gen, right?

 

Swaybar end links are fine and will re-check the lower strut bushings. Cab mounts are tight, will also look at engine and transmission mounts. Thanks for your help! And no, i believe there are no mounts. The sound comes from the either side which is the real bugger. When you jack it up it will clunk on either side when the wheels are almost off the ground and then once all the weight is released back onto the wheels and you push down on the fender... Making me think it's a frame issue, hopefully not though!

 

That shit is hard to find because metal frames transmit chassis noises all over the place. A wood dowel or broom handle makes a good redneck stethoscope, I learned that from a mechanic at work who is older and wiser than myself.

 

Yea, too true. There was three of us standing there with our ears next to the front end while someone was reproducing the clunking sound. That is a WAY better solution to find the noise, thanks!

 

Check the sway bar bushings for wear. Mine were very worn and clunking at around 200,000km. End links were fine.

 

Did some investigating yesterday on the truck and still was not manage to find it based on your suggestions. There is a little play in the upper control arm on the passenger side, when I shake it I can feel it move a little bit. The shop said this was normal but I think it may be the clunking noise. Does that make sense to you guys? Bolts are all tight on the upper control arm, think I'm gonna try to take it in to a different shop for another set of eyes. Any recommendations on what type of place I should take it? Stealership?

 

That shop is lying! There shouldn't be any slop in the upper control arm bushings.

 

Yea, i wasn't comfortable with it. They said it was a very small movement and said that much is normal. I'll take it to another shop to get another look at it when i'm in a bigger city. Thanks for the help!

 

Mine clunked bad and it was the cross member under the transmission. Tighten the 4 bolts in it - 2 either side of transfer case.

Also, check the two body mount bolts just rear of each front wheel well.

 

It would sound like it's coming from the front end.

 

I will check out the 4 bolts under the transmission tonight, checked the two body mounts on Saturday and they were snug. Thanks for the help!

 

The bolts are all super tight on the cross member under the transmission. Would the clunk noise make sense to come from the UCAs? I put FOX 2.0 coilovers in last winter and have them set at around 2 inches. That would put a bit more stress on the UCAs but I heard that 2 inches of lift with stock UCAs was fine.