Prius front suspension noise

That's not normal. My 07 doesn't do this.

Forget the dealer the dealer they'll kill you. Nothing special at all about the front end suspension on this car like any other front end. Take it to the place you by your tires from. Probably give you free estimate unlike the dealer.

You didn't list the mileage nor where you live so not sure what kind of weather the car see's so not sure how corroded the front end may be. Could either be the struts or the lower control arm or a loose stabilizer link. All mileage indicated.

You may be able to replicate this noise by pushing down real hard on each front corner.

 

My '07 has done this since 35K miles. Now at 78K miles and condition is slowly worsening. The dealer has yet to acknowledge any issue, I usually get the "normal operation" response. As edthefox5 said this is not normal.

It seems to be in the suspension. I noticed that the "clunking/knocking" sound is more pronounced when the brakes are lightly applied (not gripping) while going over bumpy pavement at low speed (<5 mph), most commonly while maneuvering in parking lots. I occasionally hear it while cornering hard at higher speeds (>15-20 mph) and also when creeping askew over steep/sharp changes in vehicle pitch, such as rolling over a driveway apron and a single wheel momentarily suspends in air. The latter can induce a longer "groan" instead of a short knocking.

The car has never been damaged. I already had the "Metallic Knocking" engine mount TSB done.

I would happily take video or provide more information to help diagnose the issue. To go one step further, I would gladly meet with a Corporate Toyota rep at HQ in Torrence to demonstrate the issue (especially considering this seems to be a common complaint. There are several threads here on PC). I am a professional engineer and have excellent mechanical intuition.

One theory i've heard is worn suspension mounts. I tend to think the shocks/struts are simply tired but Toyota will not replace because there's no visible sign of oil leaking. That's a bogus test if you ask me.

 

I'm new to the Prius, but on alot of Mk4 Golfs etc it's usually the wishbone bushings, common problem. Either replace the bushing or maybe it might be as cheap and convenient to replace the wishbone itself if it comes with the bushings fitted.

Bring the car to a competent independent and put it up on the ramp to check. It might be an anit-roll bar bushing / droplink or something small. Sometimes a spray of WD40 or similar will get you our for 10s of thousands of miles further....all depending on what it is

 

Yes, I agree that the oil leak test can result in a "false negative" result. However now that your car has 78K miles, unless you purchased an extended warranty, the shocks/struts are no longer covered under warranty.

One possibility might be for you to replace the shocks/struts at your expense. Once the old shocks/struts are removed, they can be tested via manual compression (compared to a new part) and then you will know for sure whether they have failed.

At that point, assuming you've documented a complaint about this issue as far back as 35K miles, you can apply to the Toyota Customer Experience Center in Torrance for a refund of the shocks/struts replacement costs.

 

I do, in fact, have the extended warranty. The trouble is getting the dealership to recognize and address the issue. Over multiple visits at a few different dealerships I get a variety of non-responses, such as "technician unable to duplicate", "normal operation", or even "tires overinflated" (! - I run at 40psi). Come on now.

Any tips on what to say?

 

Have you tried to demonstrate the symptoms listed below, either to the service writer or to the service technician? Also, what dealerships have you gone to? Have you tried Longo in El Monte?

 

I have the same problem on my 2006 Toyota Prius. 106,000 miles. Lately it is stating to get louder. When I park the car and rock it from the back, I hear the squeak. When I put on the emergency brake I do not hear the squeak when I rock the car.

 

Yes. I have gone on test drives with service technicians and they have acknowledged the noise, only to return from the shop 2 hours later to say there's nothing (visibly) wrong with the front end, thus "normal operation". Dealerships visited, listed in order of least-worst to most-worst; (1) Bob Smith, (2) Glendale, (3) Pasadena

I think we are talking about two separate issues. Yours is a squeak. This is a rattle. I cannot duplicate the rattling by rocking the car, nor is the noise influenced by the emergency [sic] brake. (It's a parking brake. Use it every time you Park, not just emergency parking. )

 

As previously suggested, bring it to an Indy mechanic as IMO they are much better

I see that you are in LA and I did a quick search and came up with these....

Los Angeles Tires Products - LosAngelesTires.net

 

Thanks, however independent mechanics do not, to my knowledge, honor corporate extended warranty programs.

Besides, I already have a trusted independent mechanic. It's the dealership that i don't trust.

 

That being the case, have you asked your trusted mechanic for his opinion regarding your car?

If he agrees with your belief that the struts and shocks are at fault (and by the way, I think that belief is quite reasonable given your odometer reading), that would give you some confidence in going to whichever Toyota dealer's service dept you think is best, and saying that you want the shocks and struts to be removed and inspected. If they are found to be good, you would accept the labor charge but if they are found bad then you want the repair to be covered under extended warranty.

Also, it looks like you are not too far from El Monte and I suggest you consider Longo since I believe their service dept staff are capable.

 

In my experience the "D" bushes that mount the stabilizer bar to the chassis can make a noise like that and they can be difficult to diagnose because when the car goes in the air on a 2 post hoist, the wheels hang in an unnatural position. Have someone put it up on a four post-drive on hoist and bounce it whilst listening underneath. They are often hard to diagnose because they become dry before wearing out, so appear perfectly ok when inspected, wrestling with the bar etc. They typically make the noise when diagonal obstacles are encountered as in the video, one wheel over the bump, the other not. The good news is that they are quite inexpensive and easy to fit. You could try greasing them to see if the noise disappears, although they are specified to be installed dry at factory most after market replacements are installed with grease. The genuine part has a cord impregnated into the rubber and it is when the wear gets down to this cord that the noise occurs. Not a huge prob or likely to break the bank. As others have suggested, maybe a suspension shop will get to it quicker with greater accuracy. Some dealerships have way too many apprentices and not enough real world experience on the floor. Often know all the theory without practical know how. Seen it all far too often, that's why I'm in my own shop now, less frustration.

 

It could be any of your suspension components:
Struts (See how hard it is to push down on each corner of your car) and if it comes back up firmly;
Tie rod ends, ball joints (Check for any excessive play in joints, boots ripped );
Stabilizer bar bushings;
Could even be a motor mount, although less likely.

 

Here's a video I made of the issue. I drove over 4 speed bumps:
-1st and 3rd bumps no brakes applied, no clunking
-2nd and 4th bumps brakes lightly applied (no gripping, regen only) and you'll hear creaking/crunching/clanking/rattle from the front end

 

You need to get that up on a lift and check all the things that have been suggested already.

 

Hey Rocket check this thread out:

Front end grunts over speedbumps... struts?? | Page 2 | PriusChat

You probably need new struts as the struts are pretty bad on this car. When the struts are out that's the time to check the lower control arm too by seeing how much play is in it and if you can make it clunk. Without the strut on it its pretty loose. Make sure the mechanic checks the lca's when the struts are out.

When the struts go bad they no longer are keeping dampening tension on the lca and the lca untensioned tends to move around more and if really worn will clunk.

I just went through this with one of my cars. A Sebring. I like the car but its a total piece of shit up front.
Never another Chrysler. I got it at a really good deal but like most good deals cost me twice as much.
Clunk up front. Replaced the lca's and still made clunk but not half as bad. Had to replace the struts too.
It was expensive. Chasing clunks up front is expensive. I wish I couldn't hear those noises. Or care.

When the struts are out check the ball joint on the lower control arm too. There replaceable so no big deal.
But my point is one worn part may be making another worn out part bark.
The OEM lca is not cheap $150 each.

Toyota Parts Direct - Your Online Store For Toyota Parts - Quality Toyota Parts

Never been but the bay area strikes me as a place with rough terrain. How's the roads there?

 

Hey Ed,
I'm kinda new to these Hybrids having just bought my first, second hand 05. I changed jobs, had to travel and couldn't afford to run my gas guzzler anymore. I am concerned with what you said about the struts being bad on these cars. I travel in heavy, high speed traffic daily and this has really got me worried. I'm not a car guy, what is it that's a problem with them? Should I just have them changed anyway? How much are Toyota struts vs after market? Any advice greatly appreciated. BTW, What does lca mean? Do I need these also? Please help!! I think I heard a noise the other day and the car dealer just laughed when I went back and told them. I would like to hit them with evidence if you can help, that would be great. The car steers strange, pulls to the left driving and to the right under braking. Should I park it up until sorted? You sound like you really know your stuff, so would appreciate your help!!

 

How many miles are on the odometer? If more than 100K miles I would say there is a high likelihood that the struts and shocks need to be replaced. The struts/shocks are inexpensive parts and not built for a very long service life.

There isn't much of an aftermarket for Prius struts/shocks. Toyota-branded parts are made by KYB. You can obtain KYB-branded parts on the aftermarket. Installed struts/shocks at a Toyota dealer will probably be close to $1K depending upon your local labor hour rates.

LCA: lower control arm

It sounds like your car may need its wheels aligned and the brake system checked, in addition to solving any issues having to do with a worn suspension. I suggest you have your car checked out as soon as possible.