Prius Front and Rear suspension replacement clarification

Update - I successfully replaced both front strut assemblies. Cleaned up the cowl and black plastic wiper cover area and it looks nice and new. I also replaced the sway bar end links on both side with Moog parts and that was a bit challenging and tight to get to the bottom nuts.

The old coils were about 3/4" more compressed then the new coils.

Only frustrating thing is that the clunky noise which I was hoping to get rid of is now more pronounced? It's as if installing the new struts and springs has actually accentuated the clanky noise when I go over little bumps on the road at slow speeds. It now sounds like a pronounce clunk that I almost feel on the floor of the front left end. It is smooth and quiet on the front right end, but then again the noise was always originally coming from the front left end.

At this point, I have check to identify the noise by grabbing the tire and moving it from left to right or vertically up and down but that all seems solid. I have visually looked at the joints but that looks okay, but I'm not sure what I am really visually looking for. I just don't see and tears or oil leaks.

I am thinking once I replace the rears and go to the tire shop for new tires and an alignment I will have them diagnose again and see if they can tell me what that clunking noise from the front left end is. The mechanic that looked at it with me before suspected it was the strut and that the strut was definitely bad, which it was, but the noise apparently was something else.

Any thoughts?

 

How is the front fender height from side to side now that you have the new parts in?

Regarding the clunking sound - maybe the front sway bar needs new rubber bushings?

 

Good question, the front fender heights are different by the same amount as the old springs. but now they are just both a bit higher by a little of 1/4 of and inch on both sides. So the fact that the driver side is lower must be liked you said due to uneven distribution of weight like the transaxle on driver side being heavier? I'm just repeating your comments from earlier. But driver side is still lower than passenger side.

Is your driver side lower than the passenger side?

Is it easy to replace rubber bushings on front sway bar?

Thanks Patrick for your feedback. Much appreciated.

 

My 2001 was the first Prius where I noticed this issue of the left being slightly lower than the right.
Using your method of measuring from the floor to the fender wheel opening, my 2004 is around 5/8" lower on the front, driver's corner. The rears are about the same, the left side is actually 1/8" higher than the right.
My 2015 which is brand new is around 1/4" lower on the front driver's corner. The rear heights are the same.

You have to remove the steering gear, to remove the front stabilizer bar, to replace the bushings. So this is not going to be the easiest task to achieve.

 

Found the culprit to the clunking noise. It was in the top mount area.

I had not tighten the top strut pin bolt enough on the drivers side.

I originally couldn't figure out how to tighten that bolt properly and had used my electric impact drill to get it snug.

I don't have the proper L type wrench with a hole in it to stabilize the pin while tightening the nut, but even if I did how would I be able to torque to the correct ft lbs?

I have read in places not to tighten with impact wrench, and if you must not to over tighten, so that is what I had done but it wasn't enough.

So after putting my impact to it again and letting it bapbapbap a little more I could see another thread and a half on the top so I knew it had snugged up a little more. All the while being very concerned that I might do damage to the strut.

Alas, feeling comfortable with the tightness I was able to achieve without the correct tools, I put it all back together and went for a test drive through several small bumpy roads and the clunking noise is gone.

Okay, now waiting for the other rear coil spring to arrive and onto the rear struts. Thanks everyone for your input. Appreciate the comments and help.

 

I don't understand this. If you are talking about the large nut that secures the top of the strut to the strut mount, check the torque after you have installed the strut in the car.

 

STOP. Get some proper tools, otherwise you will break off a stud/bolt one day in the near future.

Sears is currently having a sale on torque wrenches. $40 is cheaper than paying a mechanic remove a busted bolt/stud.
1/2'' Drive Micro-Clicker Torque Wrench: 20-150 ft-lb
3/8" Drive Micro-Clicker Torque Wrench:10-75 ft-lb

If you continue to work on cars, you'll need more than one torque wrench.

I own 3 torque wrenches: 3/8in (25-250 in-lbs), 3/8in (5-80ft-lbs), 1/2in (20-150ft-lbs).

 

I'm getting ready to change out the front struts on my 2006 Prius. Is this the coil spring compressor that I need?

 

Yup. I used that.

I would rent those from a big box chain auto parts store: Pep Boys, Auto Zone, O'Reiley's, etc. You just pay full retail price for the loaner tool. Upon return, your deposit is refunded. Maybe Napa has loan-a-tool program too?