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07 Prius front end clunk when going over speed bump

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Prius2000, Dec 15, 2018.

  1. Prius2000

    Prius2000 New Member

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    Hi there, some background on my 07 prius with 140k miles

    I have swap out the front sway bar and endlinks with new 05 Corolla replacement, I lower the subframe to swap out front swaybar, after test drive, car handles great, however there is this annoy clunking noise when going over speed bump, I made sure to greas the new bushing before installing, and check all the bolts were tight to factory specification, and since the swaybar bushing and endlinks are new, so very less likely they are the culprit, any ideas what this clunk noise might be? sounded like the new sway bar banging the chassis or subframe?

    only heard when going over speed bump, or sudden drop in elevation. Uneven road suface, lane markers or person hole cover does not provok this noise.

    last, i don't really remember if this noise is present before I replace swaybar, it could alway been there
     
  2. bisco

    bisco cookie crumbler

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    is it possible that there are other suspension parts that need attention?
     
  3. Prius2000

    Prius2000 New Member

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    I disconnect the endlinks and went on another test drive, it only develope more noise, and original clunk sound still present :(

    could it be engine mount? might have to pay dealer a visit
     
  4. exstudent

    exstudent Senior Member

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    Motor mount or strut mounts.

    When were the strut mounts last replaced?

    Why weren't the front sturts and rear shocks replaced, after doing all the suspension maintenance and upgrades?
     
    edthefox5 likes this.
  5. edthefox5

    edthefox5 Senior Member

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    Stab end links sometimes make a lot of noise especially if they are not oem links but auto parts store moog/China crap. Or you used the old corrola links and they were shot.

    Get under there and with gloves man handle the bar shake it hard see what’s loose.

    Clunk is usually blown strut if there original they have been dead for about 70000 miles the other thing that clunks is the lower control arm.

    Bring it to a tire shop for a free suspension front end check. Very straight forward front end nothing special under there. Pictures of how corroded it is under there please.
     
    #5 edthefox5, Dec 16, 2018
    Last edited: Dec 16, 2018
  6. Prius2000

    Prius2000 New Member

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    I beleive the motor mount and struts were never replaced, but they were visuly inspected ok, I intalled spoon rigid collars along with the new corolla replacement swaybar and reuse the endlinks that aprear in good shap.

    I did not replace the struts while was down there because I do not need to remove any suspension conponent to install above said parts. and struts were inspected ok, no leak and mounts, spring seats and rubber insulator between them were all in good shap, however I have a set of coilover coming my way, will see if that help with the clunk.

    I have disconnect the endlinks from struts, then went on test drive, it does not help with the clunk in the video, so I put everything back and torque it to factory spec. car drives amazing, with the benefit of upgraded swaybar and rigid collars, which improve "turn in feel" and mid-cornor staibility.

    I'm still very puzzeled on what it could be, here are few pictures i snap during installation!

    what do you think? IMG_0821.jpg IMG_0822.jpg IMG_0823.jpg IMG_0825.jpg IMG_0826.jpg IMG_0827.jpg IMG_0828.jpg IMG_0829.jpg IMG_0830.jpg IMG_0831.jpg IMG_0832.jpg
     
  7. Patrick Wong

    Patrick Wong DIY Enthusiast

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    With 140K miles logged, the front struts and rear shocks are toast.
     
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  8. edthefox5

    edthefox5 Senior Member

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    Not sure what rigid spoon collars are but if they replaced polyurethane bushings it will clunk pretty good.
    Solid bushings are loud that’s the price you pay to tighten up the front end. Very loud.

    And Pats post for the win your struts have not participated in ride comfort for about 70000 miles so your front end hits very very hard slightest bump will be felt.

    So solid bushings and no struts it should ride like a stagecoach.
     
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  9. Prius2000

    Prius2000 New Member

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    ^ thanks!
    coils is coming in next week, will report back after the install
     
  10. Prius2000

    Prius2000 New Member

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    After I install the megan coilover, same noise still present
    so I remove front swaybar completely the went on test drive, the noise is gone, not a single clunk, it rides speed bump so quietly like it should everything just feel right! so concludes that either swaybar(corolla replacement) or endlinks(original ones) was makeing the clunking noise
    now I'm driving around w/o a front swaybar, i notice less road feel through steering wheel, also feel little mushy
    I'm debading if I want to throw front swaybar back on!
     
  11. Prius2000

    Prius2000 New Member

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    Update: put front swaybar and endlinks back, went for a test drive, no noise!! Must be cause I removed two of the rigid collars as well, when I remove the swaybar earlier.
    finally the fault is the two of the rigid collar bushing did not seat flush where subframe and chassis meets, so it clunks whenever I go over large bump, removing them cures the clunk!

    Thanks everyone for replay! thread close!
     
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  12. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Glad you could declare victory with your front suspension work.

    I understand that you lowered the front suspension cross member when removing the front sway bar. Was it necessary to remove the steering gear as part of that process?

    How did you decide that the 2005 Corolla front sway bar was suitable as a replacement? Where did you buy that part and the links?

    What about the Megan coilovers? Did you replace the rear shocks as well as the front struts? What improvement did you notice from installing those parts?
     
    #12 Patrick Wong, Dec 25, 2018
    Last edited: Dec 25, 2018
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  13. Prius2000

    Prius2000 New Member

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    05C21B7D-C6E0-4854-9038-CC1DDE2E45E2.jpeg 72D26147-A654-45DF-9F1A-5437ED62130A.jpeg
    I loosen the steering yoke bolt, so it disconnect from rack when subframe drop, I did not have to remove additional parts, just drop the subframe far enough to have the swaybar come out from rear.

    Here is few pictures of the said falsely installed rigid collars, edge deformed due to subframe were bolting back at an angle and squeeze on the the collar.. n that created lil cap that makes the clunk!
     
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