Rear end clunking after Deaver 3Leaf AAL install

2023 Tacoma dclb sport 4x4

Installed the toytec alumaseries full lift including Deaver 3leaf AAL and I left the overload left in. (Due to getting a canopy in the near future) including new rear shocks that came w the kit.

I’ve installed many lifts before (including this exact same one, am very mechanically inclined, use to be a Toyota tech, I currently am a welder fabricator, and understand how shit works.

Anytime I go over a small quick bump, speed bump, driving thru the neighborhood with small bumps, or even to the grocery store with normalish bumps in the road… I get a clunk/rattle in the rear end. It is worse on the right side. But both sides do it.

Since install, I’ve checked the torque on everything 4 times.

I have removed the spare, no change.
Tightened up some loose fender well plastic, no change.
Loaded a set of my factory wheels/tires in the bed, maaaaaybe a slight change…

(I did not remove the entire leaf, I installed the aal in place with clamps)

It almost sounds as if it’s something on the truck rattling (rather then directly on the suspension components) due to the stiffer ride.

I have the aal shims installed that come with the kit. I do not have a CB spacer, and it drives perfect with no vibrations anywhere.

WTF?!

side note: at freeway speeds, the sound seems to be gone when hitting bumps…

side note 2: yes I’ve searched everywhere on TW to find the answer. Can’t find anything

 

Deaver 3leaf aal + shims + brand new ubolts, retorqued, + brand new toytec shocks

 

I’ve checked the little leaf bracket things (that surround the pack) and made sure they aren’t touching.

 

All tools accounted for?

 

Yessir

 

I have the same set minus the OL spring (was told by Deaver to leave it out). Deaver installed it while I had lunch. Ive never had any issues except for a squeak a couple years ago that was solved with chain lube. Try removing the OL. I've loaded it down a lot and it still doesnt bottom out unless I hit a dip hard with load.

 

Best bet might be a GoPro or a phone secured to the underside and a quick ride around. Need more data for troubleshooting.

 

Is this picture taken with the truck's weight on the rear suspension or at full droop? Just wondering if the sound is the shocks going to full extension driving over bumps.

 

I will pull overload out, and see what happens. Shocks are meant for this lift, so they have plenty of travel.

 

^Put the tires on, then jack up the axle one side at a time. How close does the rear tip of the AAL get to the OEM keeper bracket?



Also check the AAL front keeper bracket bolt tip isn't hitting the fuel tank strap on the driver's side.

 

They both clear front and back from the oem bracket. And nothing hittin fuel tank strap

 

Take a look at the rivet holding the bracket on the overload leaf. When i first installed my AAL keeping the overload, that rivet would chatter a bit on bumps against the lower leaf, mostly at low speed. Eventually it flexed the overload ends a bit and stopped making noise.

 

Alright guys… got an update.. I’ve spent the last couple weeks tryin to figure out this f*cking noise. Can’t find out.

I decided this 3leaf aal w/ overload was stiff anyways, so I just replaced my leaf pack with the OME 111R (medium) pack.

Went for a drive…. PROBLEM IS STILL THERE! What in the actual f*ck?! Lol.

I don’t know anyone that has had this before. I’ve read all the threads on TW. Google. YouTube. Etc etc etc.

What next?

 

Shock mounted properly? No slop in the upper or lower bushings?

 

Shock mounted properly.
Even with shocks removed, still makes clunk.

 

U-bolts torqued properly? Hangar bushings tight inside the eye?

 

Yes

 

A few thoughts…
You said you tried it with the spare tire removed. Did you try securing the dangling chain with a bungee or something to rule that out?

Are you 100% sure it’s coming from the rear and the sound isn’t reflecting from the front to the back? I ask because I forgot to tighten my front sway bar links in my old 4runner a while ago and it rattled and clunked over bumps until I figured out it was loose. But it sounded to me at first like it was coming from the back. Maybe have a buddy drive your truck over a bump with you outside next to the bump and see if you can see/hear anything better from that perspective.

Are you U bolts sitting flush against the top leaf? I don’t know if that would cause a noise or not, but when I installed my AAL, the U bolts that came with it were 1-2mm shy of being wide enough to fit around the stock leaves. So only the corners of the U touched the top leaf, with a mm or 2 of space between the leaf and the middle of the U (instead of sitting flat against the leaf). I ended up reusing my stock U bolts because they were still long enough (with the overloads out) and at least they fit properly around the leaf packs.

On the pic of your rear shock, it look like the little silver “button” thing on the upper collar (I’m guessing it’s a port to recharge the shock??) could be hitting the upper mount.

 

I have done it with spare removed AND chain bungeed solid in place.

100% rear. When going over speed bump, front is perfect no noise, and then rear hits it makes noise everytime.

yes I had my wife drive it back and forth over the bump and I had my head next to rear wheel well, and it made noise and I could hear it.

Yes ubolts are wide enough and fit as they should.

the silver button is not touching anything.