cambob

I've got what I think is a front end clunk on my 94 4runner, 3.0, auto. List of things I've done/tried.
1.) Most of the front end suspension is new - tie rod bushings, control arm bushings, both steering arms, lower ball joints, new shocks all around.
2.) I jacked up the front end the other day and did the tire push/pull tests for ball joints/tie rods. Little to zero movement in any direction, so I figure the upper aren't bad yet and the boots aren't torn. Wouldn't I be able to move the tire if they were? Or see movement in the joint?
3.) Today, I replaced the front sway bar to frame bushings since they were bad. No dice, clunk is still there.
4.) Also tried driving with hubs locked and unlocked, no difference. If it was a CV problem wouldn't the sound go away with them not locked in?
5.) Doubled checked torques up there, checked for stupid things like loose skid plate, missing wheel weights, tire pressure. Checked the drive shafts for any looseness and made sure they had grease.

I'm running out of ideas and sick of feeling terrified that something is going to come loose on the highway :0 The steering feels okay (responsive), but something about the ride is a little wonky. Almost like worn out shocks, but they aren't... As always, any advice is greatly appreciated because I'm really scratching my head on this one!

cambob

I guess relevant information to add would be that this clunk happens over almost every bump, even the small ones. Doesn't matter if I'm going straight or turning.

scope103

can you get the clunk just by jumping on it? If so, you might have a friend do the jumping while you've got your head underneath.

abecedarian

Are the battery, radiator overflow and air filter housing secured? Loose bumper bolts?

Old upper ball joints, drag link, pitman arm?

cambob

The upper ball joints have not been replaced recently (were on there when I bought it), but it passed the tire movement test while up in the air and the boots look good. Everything I could think to check is secure and I did check all the stupid stuff like battery holder, skid plate, etc, but I'll be double checking everything. Any possibility it could be the control arm bump stops making noise? The rubber looks pretty old, but they are intact (no chunks missing or anything).

abecedarian

I'd think that even if it makes noise on small bumps, and has new shocks, you're not hitting the upper stops- that's about what, 3" up travel at the wheel before you hit the stop?

Checked the body bushings?

cambob

Yeah, I think its about that much travel. I put KYB Gas-a-justs on it about 7k ago and they pass the push down on the bumpers test, so I can't imagine they are already toasted. I have not checked the body mounts though, but will be tomorrow. I'm going to do the uppers next week too just to completely eliminate them for the clunk hunt. Thanks for the suggestion, thats something I hadn't considered!