Pop/Clunk noise from front when turning slow? [FIXED]

[Dempsey510]

Hey all,

I have no idea where to go now with this as its been a few weeks now and have gotten nowhere really, The clunk noise it makes whenever Im doing a slow turn in/out of driveways and U-turns where I nearly go full-lock

Here is a list of the changes I have made to my Hilux over the weeks turning into months now...

- New 2.5" (60mm roughly) Lift Front and Rear
- Blackhawk 3 degree fixed offset UCAs
- Blackhawk Swaybar relocation brackets (Useless without the Swaybar)
- PhatBars Diff drop
- New front CVs (3rd Set)
- Wheel alignment done
- SuperPro Rack bushes replaced
- Pedders suspension test completed with no faults?
- Sway bar links pins and D-Bushes (Removed the whole sway bar for testing and noise is still there)

Pending/Untouched parts:

- SuperPro fixed offset Lower Control Arms
- New Rack ends/Tie rod ends (I bought them but have not put them in yet)
- Maybe new steering rack?

Next steps:

I'm am about to take the whole front diff and CVs out of the car and see if the noise is still there after that, Even if I need to sacrifice a set of CVs and cut the ends off just to bolt the ends to the wheels then so be it, So fed up at this stage

Could the noise be from something as simple as a steering rack? I have a new in the box one sitting here

Video:

2nd gear, right turn and yes the CVs are brand new

https://youtube.com/shorts/Y7BsBHNKdjY?feature=share

UPDATED VIDEO (Under vehicle view)
https://youtu.be/PQQPWvDK5JM

[martynvella]

Id be thinking CV joint.

[martynvella]

Id be thinking CV joint.

[hiluxxury]

How many Kms on it. Could be any number of thing including the CV but also look at the wheel bearings or something simple like the control arm nuts not done up properly.

[Rob_Wood]

Id be thinking CV joint.

I was thinking the same thing, but he already says he's got new CVs in it. I guess double check the new ones are the correct CVs and then work your way down the list, Double and Triple checking all the work you've already done, making sure the parts are correct for the install AND that nothings loose. Then I'd be looking at the "partially completed" upgrade mixing old and new components that somehow mismatch. If that's it, then complete the upgrade, ensuring ALL the new components are right for the job AND they are compatible with the other "Upgrade Components" you've already installed
Please let us know how you go.

[Chopps]

Sway bar hitting coils

[hiluxxury]

Yeah that was my thought as well... but you'd think that Pedders would have picked it up

[Chopps]

Possibly sway bar rubbing on bash plate/ standard tins but "pop/clunk" sounds like coil interferance
No mention of sway bar relocation
Replicate noise - stop vehicle immediately when heard, maintain steering lock and have a look for contact.
Alternatively look at the lower coil for missing paint between the sway bar. Difficult to see missing paint from sway bar link end inners.

[Dempsey510]

So I have replaced the CVs again with the non extended ones due to having a diff drop I've been told I need standard and not extended I have even replaced the sway bar links with brand new nolathane ones and the D-bushes.

As well with the blackhawks swaybar relocation brackets they should not hit the coils.

My only other thought is the bushes on the steering rack itself I plan to do those today or tomorrow and see how that goes.

[dave g]

Have a look at the steering stops up against the bottom control arm put same grease on them and when you got full lock on back the steering wheel off just slightly so they can slip against each other.
You have changed all the geometry so they could be digging in.

[Rob_Wood]

Just thinking out loud here. Check for wear marks on your tyres, bullbar, sliders and Guard Liners. Only reason I'm saying this is coz' ... I dunno why. Just trying to suggest you double and triple check everything, even stuff you haven't worked on recently.

[mark409]

Recheck all the bushes on your new suspension lift.

[Dempsey510]

Recheck all the bushes on your new suspension lift.

Gone over everything with the torque wrench and all is tighten to spec, I have the SuperPro steering rack bushes and new arms I'm gonna put in tomorrow as well as some grease of the steering stops as mentioned above and see how it goes

Will post updates

[Dempsey510]

Updated main post with video as well

[Chopps]

Good to post the video. Doesn't sound like coil interference but video can be misleading
Doesnt look like there is much if any any vertical articulation involved
You can replicate this while stationary. You could try:
Get 4 thin plastic chopping mats from supermarket
Place two on a flat surface wheel width apart add a squirt of dish washing liquid on top then place the other two boards on top.
Roll slowly on top of the boards using your hand brake only to stop - if you use your brake pedal you will slide the mats off each other.
The wheels will now turn left and right with little resistance
Turn wheel in the direction you described
See if you can replicate the sound when driving and pin point the location of that noise

The above will also work using 200mmm ply wood squares.
You can jack up one wheel at a time to see if vertical articulation makes a difference

[Dempsey510]

Good to post the video. Doesn't sound like coil interference but video can be misleading
Doesnt look like there is much if any any vertical articulation involved
You can replicate this while stationary. You could try:
Get 4 thin plastic chopping mats from supermarket
Place two on a flat surface wheel width apart add a squirt of dish washing liquid on top then place the other two boards on top.
Roll slowly on top of the boards using your hand brake only to stop - if you use your brake pedal you will slide the mats off each other.
The wheels will now turn left and right with little resistance
Turn wheel in the direction you described
See if you can replicate the sound when driving and pin point the location of that noise

The above will also work using 200mmm ply wood squares.
You can jack up one wheel at a time to see if vertical articulation makes a difference

No matter what I do I can not under any circumstances recreate the noise while vehicle is not in montion

Updated main post with new information

[goodiestgoodman]

Might seem very simple but worth a mention, are your tyres hitting your body mounts on full lock?

If you're running 33's without a body mount chop this could be an issue.

Good luck

[Dempsey510]

Might seem very simple but worth a mention, are your tyres hitting your body mounts on full lock?

If you're running 33's without a body mount chop this could be an issue.

Good luck

Nah my tyres clear all round

285/75/16 on a 0 offset

Thinking its the power steering rack and the ends or my lower control arms its the only parts still stock

[hiluxxury]

Cracked chassis? It sounds like old work cruiser I drove years ago.

It's very uncommon unless you are into jumping your hilux, but I'd check the strut tower and the welds around the LCA hinge mounts. The welds cracked in a couple of 120 prados and I've seen cracked strut towers on this forum.

[Dempsey510]

Cracked chassis? It sounds like old work cruiser I drove years ago.

It's very uncommon unless you are into jumping your hilux, but I'd check the strut tower and the welds around the LCA hinge mounts. The welds cracked in a couple of 120 prados and I've seen cracked strut towers on this forum.

Really hope not, Will have a closer look later tonight