Ok, here's the deal. I've got a customer who installed Donahoe Racing Long Travel 2.5" coil overs with Camburg Uniball upper control arms on his 03 Tocoma 4x4 TRD. He brought his rig to our shop to figure out a clunking noise from the right front suspension after installing this kit. I am able to reproduce this noise both on and off the rack and with the right wheel off, in 4x4 or not, by moving the vehicle forward or backward and then abruptly applying the brake. The noise is a metal binding noise, (much like the noise heard on older Toyotas when you turn the steering all the way one way and you hear that metal binding noise from the steering stops). The noise seems to be coming from the right side, front upper control arm bushing area, but even with a stethoscope it is hard to pinpoint because of the noise travel through other metal components. It may be coming from the axle. I have checked tightness of all suspension bolts/nuts and lubed all areas I thought might be the source of the noise, but have not been successful as of yet. The customer did not do the front diff. drop either.
Anyway, I was wondering if anyone has heard/had this problem with Donahoe or Camburg kits, know of problem areas during installation that the customer might have fell into, or if you have any ideas/suggestions that could help aid in remedying this problem? Thanks for you time.

 

Might want to post this on TTORA - a lot more people running long travel Tacos over there.

 

Maybe the wrong bushings or a defective bushing? I know that makes a big difference. Try contacting the guys at Protrux. they have a lot of experience with that stuff. www.protrux.net