2nd gen Tundra upgraded with 2.5 gen parts; now front clunk when turning

I have a 2007 Tundra DC 4wd 5.7 that I just had the front diff replaced from a 2016 donor, both front strut assemblies replaced from a 2018 donor, and both CV shafts replaced from a 2020 donor.

I did this because the front diff was making the wu wu wu wu sound (and had potential gear whine, with other issues) so I replaced it along with the other items mentioned above, while also removing the existing diff drop and 3" leveling kit. I removed the diff drop and leveling kit because I had read that it can be the cause of diff failure, so it only seemed appropriate at the time.

This was all done on the same day, same time and also had a front-end alignment performed twice, because the steering wheel can't be made perfectly straight anymore; it is turned slightly right to go straight.

Additionally, I now have a hard metal clunk / clunking sound when I turn left, while driving slow over mildly uneven surfaces; like leaving a business onto a road with a small water drainage runoff channel separating the two. Other than this it drives smooth and straight with no issues. I should mention that I had the left front wheel bearing replaced about 1000 miles ago with OEM parts, so it's not that.

I've researched and found others online experiencing the same issue, but most have never found the cause. Well, you can probably narrow it down to the parts I replaced, since I never had this sound before.

All of the used parts looked like new and were from Tundras much newer than mine, which is why I felt safe installing them.

Sadly, my Tundra lost all of its "personality" from the removal of the leveling kit. It doesn't display the same confidence as before, but it drives great.

 

For the clank, check obvious things first like a tire rubbing on the skid plate when you turn.

 

The skid plate was already removed and gone when I bought it. I think the previous owner couldn't reinstall it after the diff drop was installed, so he disposed of it.
My tires are a little oversized at 275/65/20, which fit great with the 3" leveling kit, but are a little tight now.
However, the hard clunk sound is distinctly metal.

I once test drove a Tundra with extremely oversized tires and lift, and that rubbing was just rubber on plastic inner fenders during tight turns.

 

Check alignment cams. Make sure the tabs aren’t flattened and they’re torqued to 200lbs.

 

Check all your suspension hardware, it sounds like loose cam bolts

 

sway bar end links, UCA hardware too.

 

I had my mechanic put it back up on the lift and take a look while I stood there and everything is tight and right with the suspension. He did find that my right front wheel bearing is loose, so that will get addressed next week, but the clunk sound seems too extreme for a loose wheel bearing. However, I could be wrong.

 

They sell OEM Koyo Bearing Complete Hub units on eBay for about $150 if you search

Bolt on ready to go

 

Thanks, I took your advice and bought one from ebay. I knew it was the right choice when I saw that they're made in Japan, not China

 

There are counterfeit koyo bearings on the market. So at that price gotta be careful.

 

interesting. source?

 

You can find more info on this topic if you google it. Some other forum pages have more info on it, with photo documentation.

https://koyo.jtekt.co.jp/en/2021/05/news210519e-02.html

 

Could be a bad strut or CV's or any front end bushing. Or if the alignment isn't centered could be the bump stops on the knuckles making contact.