I have a 97 4Runner 4WD V6 that I just had new Bilstein front struts installed from a reputable garage. The first time I got it back, there was a noticeable rattling from the upper front when going over small bumps. I took it back and they said that they had installed the old bushings the first time as they still looked good. This time they installed new bushings. When I got it back the second time, there was a big improvement but I still hear a thud, thud when hitting larger bumps etc. I know the Bilsteins are super stiff but I still don't think I should be hearing this noise. I've been told that there could still be a gap as a result of the strut mounts being worn but I don't know. If they are, the mechanic should have told me so. The old stock struts didn't make this noise. What could cause this and should I take it back a third time? They seemed like they knew what they were doing but I was irritated that it went out the door the first time with an obvious clunk, and a second time with a less noticeable but still annoying sound. I would appreciate anyones feedback. Thanks a lot.

 

If it's making noise now it didn't make then take it back. No way to diagnose a "thud" over the Internet. It could be anything.

:wabbit2:

 

How loud is it? Describe it better.

 

It's not crazy loud. More like a dull knock for a split second after I hit a sizeable bump. Can't hear it as much when its just a little bump in the road but more noticeable if several bumps or washboard surface. Maybe its normal and I should just leave it alone. Just thought I would get this great, but stiff ride, with the Bilsteins. Instead, it feels worse, rides like tank, and has this noise compared to the original struts which had 130k on them. Disappointed. Thanks a lot.