Have them re-balance the tires.

Then we can go from there! :thumbup:

 

I have been hearing a slight rattle/clang in what seems like my front drivers brake under rough conditions as well. I am going to take it in and see if it is loose suspension or maybe the plates. Keep us posted.

 

Five months later, have you guys found any resolution to this problem? I certainly hope so, as I have the exact same thing happening and it's driving me insane.

A healthy clunk from seemingly right under my left footwell at low speeds, while applying or releasing the brakes with the wheel turned more than 1/4 travel to the right. It can be felt slightly through the brake pedal itself, though I believe it's just passing along the shock from the frame/suspension. Also get it when releasing the brakes in reverse, regardless of wheel direction. Similar noise when going over washboards or rought terran. In the course of my investigation, I found that the noise can be replicated with modulation of the throttle while in 4HI. Looking at the wheel as the noise occurs, it seems to shudder, just a degree or two of wobble associated with the clunk.

It's not the known cab mount nor the bumper mount issue. I've pulled the wheel off, I've checked every piece of hardware in the wheel well (left front), it's not the skidplate (pulled those off today, hoping). I've taken a rubber mallet and just banged on stuff but was unable to replicate the noise. I even rotated the tires, not that it was likely to help. FWIW, mine's an '06 DC TRD Off-Road, 3" Revtek. Stock tires, for now - I'd like to fix the present issues beore creating new ones. The alignment is fine, tires in balance. About 14k miles, but it's been doing this for at least the last 5k, if not longer.

As an aside, I did find the source of a tiny creaking noise by accident. A brake-line bracket sits on the aft part of the upper A-Arm. It appears that the current alignment had the A-Arm sitting rather far forward. such that the bracket on the arm rubbed against the coil spring. I pulled the brakcet, ground it down, and now it doesn't rub. Now as I write this I have to wonder, is there a connection with the first issue relating to the upper A-Arm being way forward in its adjustment? Is it ever even supposed to move?

 

I started hearing a rattle under my truck after installing TRD exhaust when hitting small potholes and bumps. Drove me crazy till I found out it was the exhaust connection up front. This is the connection with the 2 spring loaded bolts. I could make the noise by twisting the exhaust at the tailpipe and letting go suddenly. The 2 holes in the TRD catback are much bigger than the bolts that go through them so the whole exhaust can be spun slightly so the flange taps the bolt when it moves. Check it out.

 

I started hearing a rattle under my truck after installing TRD exhaust when hitting small potholes and bumps. Drove me crazy till I found out it was the exhaust connection up front. This is the connection with the 2 spring loaded bolts. I could make the noise by twisting the exhaust at the tailpipe and letting go suddenly. The 2 holes in the TRD catback are much bigger than the bolts that go through them so the whole exhaust can be spun slightly so the flange taps the bolt when it moves. Check it out.

Yes, its this.

 

I started hearing a rattle under my truck after installing TRD exhaust when hitting small potholes and bumps. Drove me crazy till I found out it was the exhaust connection up front. This is the connection with the 2 spring loaded bolts. I could make the noise by twisting the exhaust at the tailpipe and letting go suddenly. The 2 holes in the TRD catback are much bigger than the bolts that go through them so the whole exhaust can be spun slightly so the flange taps the bolt when it moves. Check it out.

That's good info to know, as I ordered my TRD exhaust on Monday. I'll look into larger diameter bolts before the install, hopefully avoiding this issue. Thanks for the tip

 

My weird clunking I can hear when moving or sitting still in the driveway, usually on days when the temp is below 55 degrees. Sounds like someone is slapping the firewall with a rubber hose, mash the gas it beats faster. But the dam noise is intermittent so I havent been able to track it down or even where to start.

 

That's good info to know, as I ordered my TRD exhaust on Monday. I'll look into larger diameter bolts before the install, hopefully avoiding this issue. Thanks for the tip

i wouldn't start looking for larger bolts just yet.... because, the bolts remove from the rear. and, the nuts they secure to are welded to the stock y-pipe. you could only use that thread size.... it's possible a sholder bolt might work? but, sometimes trying to find metric stuff is difficult. i had no problem installing mine, it's a spring loaded bolt on connection for a reason. probably for flexing... i did need assistance from my 4yo dayghter to lean on the tail-pipe helping to align the bolt-holes while inserting the bolts....

 

I had a muffler shop install the catback. Toyota wanted $240.00 for 2 1/2 hours labor but thats a different story. When I found out where the rattle was coming from I took the truck back to the muffler shop. I showed him how much play was in the exhaust and he suggested either welding some extra brackets and using heavy duty rubber hangars or just putting bolts with washers and no springs to hold everything tight. Laying under the back of the truck under the exhaust tip, I can spin the catback and can see alot of play at the connection flange side to side. If you spin the catback back and forth quickly the flange hits the mounting screws and makes the same rattling noise I could hear when hitting bumps. I still have the original exhaust and compared it with the TRD and except for the muffler they are identical. I don't know why the original didn't rattle, maybe because it was heavier and stayed in place better.

 

I had a muffler shop install the catback. Toyota wanted $240.00 for 2 1/2 hours labor but thats a different story. When I found out where the rattle was coming from I took the truck back to the muffler shop. I showed him how much play was in the exhaust and he suggested either welding some extra brackets and using heavy duty rubber hangars or just putting bolts with washers and no springs to hold everything tight. Laying under the back of the truck under the exhaust tip, I can spin the catback and can see alot of play at the connection flange side to side. If you spin the catback back and forth quickly the flange hits the mounting screws and makes the same rattling noise I could hear when hitting bumps. I still have the original exhaust and compared it with the TRD and except for the muffler they are identical. I don't know why the original didn't rattle, maybe because it was heavier and stayed in place better.

regarding your twist.... something doesn't sound correct. i can't remember if there was a steel gasket between the catback and ypipe flange? can't remember? but something kept the two flanges aligned..... next thought... try sliding a small piece of rubber hose snug to the threads, but long enough to bump the inside of the catback holes ( like a bushing ) isolating the steel to steel bump between the bolt shaft and the holes inside diameter??? just a thought...

 

regarding your twist.... something doesn't sound correct. i can't remember if there was a steel gasket between the catback and ypipe flange? can't remember? but something kept the two flanges aligned..... next thought... try sliding a small piece of rubber hose snug to the threads, but long enough to bump the inside of the catback holes ( like a bushing ) isolating the steel to steel bump between the bolt shaft and the holes inside diameter??? just a thought...

I was thinking the same exact thing and actually have some tubing in the truck. Just havn't had the time to try it yet. Bolts were going to be a last resort. Afraid of overtightening and maybe bending the flange. I also checked a toyota parts site and the only thing they show is the donut gasket. I was in the garage when they swapped catbacks and didn't see anything fall out when they took the original off. Thanks for the great ideas.

 

I notice some clunking when going over speed bumps. They seem to come from the rear suspension when going at moderate speeds. At slow speed the noise is not there. I'm sure this is probably not the same noise you all are reporting. Can anyone shed some light on this. I've tried to figure out but can't, thought it maybe related to the exhaust, but to no avail. I appriciate any feedback.

 

I notice some clunking when going over speed bumps. They seem to come from the rear suspension when going at moderate speeds. At slow speed the noise is not there. I'm sure this is probably not the same noise you all are reporting. Can anyone shed some light on this. I've tried to figure out but can't, thought it maybe related to the exhaust, but to no avail. I appriciate any feedback.

Are you sure it's coming from the rear? I could have sworn the rattle I had was coming from the rear also. Just before I put the exhaust on I also put a Lorado tonneau bed cover on. Thought it was that but everything was tight. Checked rear license plate and everything else in the rear. Every time I thought I found it I was wrong. Could hardly hear it with windows closed. Louder with side windows open. Louder yet with rear window by bed open. It had to be the rear of the truck. But it was loudest when I opened the drivers door and could finally track down where the sound was coming from. My rattle was at its worst when driving around 15-20mph over several potholes in a row. To slow or to fast no rattle. Check out the whole underside of the truck cause the sound could be traveling from somewhere other than the rear. Just a thought.

 

Are you sure it's coming from the rear? I could have sworn the rattle I had was coming from the rear also. Just before I put the exhaust on I also put a Lorado tonneau bed cover on. Thought it was that but everything was tight. Checked rear license plate and everything else in the rear. Every time I thought I found it I was wrong. Could hardly hear it with windows closed. Louder with side windows open. Louder yet with rear window by bed open. It had to be the rear of the truck. But it was loudest when I opened the drivers door and could finally track down where the sound was coming from. My rattle was at its worst when driving around 15-20mph over several potholes in a row. To slow or to fast no rattle. Check out the whole underside of the truck cause the sound could be traveling from somewhere other than the rear. Just a thought.

When the windows are up i can't hear anything, however when they are down its a completely different story. At first i thought the spare was loose, checked it and looked to be as tight as possible. I'm starting to wonder if its not related to the shock blades on the rear suspensions. The same applies to when going over pot holes. Its just aggravating and driving me nuts. If anyone has a fix for this issue or is experiencing the same, please share your story.

 

not sure if this is an apples-to-apples comparison to the above issues, but I finally got an elusive undercarriage rattle fixed today, and had to diagnose it myself. Noticed a moderate-to-severe rattle eminating from the undercarriage each morning during the first few minutes of driving, most noticeable with the window down and when driving by good sound reflectors like the 6-foot wooden fences in my neighborhood. Ended up being the drivers side secondary catalytic convertor heat shield being loose when cold. Noticed one morning in my garage that if I touched the drivers side secondary cat when idling, the rattle went away - and this is what I imparted to my Toyota dealer, which they fixed today with a new heat shield and mounts. p.s. Per the engine tick TSB, had the manifolds and primary cats replaced a few months ago, and it did run quieter, but this particular noise was much more aggravating.