2022 Frame Replacement - What is this Noise? Update - Noise Found

Hi All,

Have a'22 TRD ORP lifted 2.5 inches with an Icon lift. Looooooong story, but the truck has almost 7k miles but is on its second frame. The frame replacement was done by the Toyota dealer I bought it from, who also did the Icon lift/wheels/tires (bought new with lift/tires already done).

The dealer did a great job with the frame replacement, but there is some sort of pop/bang still lingering after a few attempts to remedy. Video attached. It only occurs at low speeds, not when going over bumps, usually in reverse or coming to a slow stop, sometimes when the wheel is turned. I feel like it is correlating with the steering somehow.

I know this is very little info, and virtually impossible to diagnose over the internet. Just hoping for some constructive feedback as the truck has been at the dealer a few times now trying to narrow it down.

https://youtube.com/shorts/lHC6o63nXns

 

Frame replacement on a 22’?

 

That’s what I want to know more about.

 

I'm surprised that dealer did the lift my dealer said that it will void warranty.

 

A frame replacement on a 22 has to involve some special circumstance, so give the guy some slack.

OP, I can hear what you’re referring to, but just hearing the sound doesn’t seem to be enough to tell what’s going on. A frame replacement is so involved, it unfortunately could be anything…

 

Have you had a buddy walk next to you while driving slowly to start zeroing in on side / general area? Almost sounds like a loose endlink or bar, but I guess I’d expect you to hear it on speed bumps too

 

You are right. I deleted my post as unnecessarily combative, though it would be interesting to hear the back story.

 

Yes, unfortunately. Ran into a large (large) curb, basically a giant boulder with the front left wheel. I was trying to avoid something else, but the tire sidewall caught just enough that it ripped the steering wheel out of my hands and the truck went 5 mph to 0 mph instantly. Blew LCA/UCA/steering rack etc... and ultimately discovered the frame was bent in multiple places, primarily the front shock mounts.

 

I'm kind of curious as to what the original combative post said

 

Have tried that personally and the dealer has as well. it is definitely coming from the front left. It is so random and bumps don't trigger it at all, which makes me think it is not suspension (dealer has re-torqued the suspension multiple times now). I think you might be on to something with an endlink.

 

Take the skids off (could be clanging against something) and remove the endlinks and/or swaybar (you don't need them so don't worry about ruining anything), drive around a bit and see if that fixes your problem - if it does you know what to fix. Should take ~15 min of wrenching

even a small (visually hard to tell) amount of play can cause clunking

 

This is great advice, thank you. Personally I have been thinking it sounds like something has been hitting the skid, I can take that off since I installed it (it's the silver TRD one) and my buddy will know how to remove an endlink and/or swaybar (knowing me I would disconnect the steering tie rod ). Excellent advice, thank you!

 

it said I couldn’t imagine a warranty issue where I would accept anything but a new truck and I asked if it was wrecked.

knowing now it was wrecked, the warranty frame replacement comment is moot. Just didn’t want to come across the wrong way, especially as a noob here, so I took advise from another forumite to give some slack and not be presumptive.

 

that sucks.

 

All good, I would have thought the same thing Welcome to the forums !

 

Yup, it sucked. The biggest bummer is it happened in June and I just got it back a couple weeks ago and still have this lingering issue. I really think something is hitting the skid plate so I am going to remove that and the end links per another comment and see what happens. It will get sorted out somehow, thank God for insurance.

 

Since it seems to happen over bumps and when there is spring compression in play, inspect both front springs to look for rubbing form another suspension component.

 

I heard a similar loud clunk one time driving forward and sharply turning right in a parking lot. It was a very loud clunk noise but i havnt been able to reproduce it. It was definitely alarming when it happened

 

Wow, sorry to hear.

 

The unfortunate thing is that it does not happen over bumps, only when moving slowly, usually turning and usually in reverse. But, it is random at the same time.

 

Yes, sounds the same as my issue, it can be very alarming!

 

Remove one thing at a time, test drive it and if noise there then remove another item, rinse and repeat until you find what item is causing the noise.

 

I am a tad surprised that Insurance did not give it a Totaled write off, or did you have to pay a substantial amount of the total cost?

 

Typically the cost of repairs need to be 80% of the market value of the car for them to total it. Repairs were close to $28k but it is a '22 with 6k miles on it, not to mention it was purchased from the dealer with the lift/wheels/tires, so Insurance considers that part of the value. I just paid my deductible.

 

Oh no!!! Are you telling me this happened after the Hole in the Rock Utah misadventure???

 

That is correct old friend

 

At least you’re rolling again.

Some random suggestions:

-Spend some time just trying to reproduce this sound consistently, trying different things that might have caused the clunk in the past. Honestly, this will be the most helpful thing you can do.

-suspect any parts that were not replaced in either of the incidents, if they could have been possibly damaged….

-suspect an assembly error somewhere. Frame replacement is simple in theory, but extremely labor intensive, with lots of steps that can be missed. Even with good techs.

-get a go-pro and mount it somewhere suspected of making the noise. You may catch some movement red handed (not necessarily though). If you do this, take the skids off.

My guess. The front shocks are loose…or a sway bar is loose. Or a swaybar is missing a bushing, or loose bolts on the transfer case crossmember…. Hell a loose bolt anywhere that is supposed to hold weight or pressure…it sounds like a very physical noise. It should be spottable if you trace your way through things (while you sing “the leg bone is connected to the hip bone…”).

Find some way to get comfy so you can just lay down and look and touch. Enjoy the your time looking and appreciating the machine. Look under driver front, study, pass front, study, center front, study, transfer case area, study. Take pictures to study later. Speak sweet nothings…it will eventually reveal it’s secrets.

 

Wow I was way off on the cost then I estimated 35K plus for a full frame swap.

 

Yeah, meanwhile a guy posted about hitting a deer and banging up his front end and getting a 38k repair bill?!?

 

Yes and that is what I was thinking ... but then maybe that is why there are Rattles?