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Old 02-10-2018, 02:39 PM   #1
06YarisRS
 
Drives: 06 2ZR Turbo Yaris RS
Join Date: Aug 2017
Location: Fredericton, New Brunswick, Canada
Posts: 2,384
Links, Boots and Pins - Finding the Clunk (LONG)

This month's project...find the front end clinking/clunking/rattling and eradicate it...

For the past few weeks I have been experiencing unwanted noise from the front end, basically when I drove over cracks in the road and small bumps. I had the car up on the hoist and checked every conceivable fastening point, bushing. EVERYTHING was as tight as could be with the exception of what seemed to be slightly loose calipers.

I took the car to a local shop and they said they weren't sure but recommended end links. I explained that I thought it might be the brake calipers rattling and being amplified through the body. They said "No way, wouldn't make that noise" and this after they did a road test. So, new end links installed and guess what? No change in noise. When the shop was cutting off my old end links, they burned a hole in my passenger side CV boot. I didn't bother going back as I'm sure I would have been charged to have that replaced too, so I ordered a boot locally and another shop put it on. The second shop only charged $30.00 to install the boot. It is not like me to farm out jobs like this normally but I just wasn't feeling like wrenching this time around. Nor did I feel like waiting for another order from rockauto.

We had the perfect day for testing my brake theory. We had about 1.5 inches of ice on the roads and the salt trucks turned the roads into washboards. I could drive along with all the clattering, clanking, touch the brake pedal and the noise would go away. So, I removed the calipers, thoroughly cleaned and regreased the caliper slider pin channels and installed new pins. The small rubber flat o-ring on the ends of the caliper pins (one pin per side) were completely torn and flattened. Anyway, new pins in and my front end was blissfully silent again...for a couple of days...

This time, I started getting a loud clunk over larger bumps. The clunk had a sort of ringing sound, sort of like what it would sound like if you whacked a strut spring with a rubber mallet - a ringing sound along with the clunk. I had a buddy rock the car back and forth and could see the top end of the passenger side end link moving up and down - sticking, then letting go. The sway bar would snap down as the top of the end link slipped. I tightened the upper nut down - it was not very tight - and now I am back to sublime silence. The car drives like new. I do think that the new end links did help to stiffen up the front end a bit, so all was not lost.

Anyway I thought I'd share, mainly to suggest that worn cailper pins on the Yaris can cause one heck of a racket as the jiggling caliper really reveberates through the suspension components. At least something to check if you're having trouble nailing down an annoying front end rattle/clunk.
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2006 Yaris 5 Door RS 2ZR-FE (2011 Corolla 1.8L) Swapped, Automatic, T-28 Turbocharged (8 psi), HSD MonoPro Coilovers, DIY W/M Injection, custom 3" cold air intake, custom 2.5" exhaust, TRD rear sway bar, Penguin Garage 13mm spacers (rear), custom Civic front lip, full repaint, Android 6.0 7" touchscreen, Rockford Fosgate speakers, tweeters, NVX underseat subwoofer
https://www.instagram.com/2zr_turbo_yarisrs/

Last edited by 06YarisRS; 02-20-2018 at 06:09 AM.
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