Front suspension replaced, now a clicking. Help troubleshoot?

Did you tighten the nut in the center of the top strut mount? The tightening torque is 35 ft.-lb.

The tightening torque for:
the three nuts that hold the top strut mount to the body is 29 ft.-lb.
the two bolts at the bottom of the strut to the steering knuckle is 113 ft.-lb.
the link to the antisway bar is 55 ft.-lb.

 

Clunk sounds are generally from improperly torqued fasteners as Patrick is suggesting above or another suspension part that has worn (e.g. sway bar bushing, sway bar connecting link, rack and pinion bushing or lower control arm bushing as examples).

If your torque values are confirmed appropriate, elevate the front end of the vehicle to take the load off the suspension and start visually inspecting and physically checking the other suspension/steering components.

 

113 ft-lbs by feel? Some auto parts stores rent tools if you can’t borrow one.

 

Less likely, but it could be a CV joint making the noise. I would first look at the struts you just installed.

 

Is it the same torque for 2008 Gen II Prius Struts? I am thinking of replacing my struts and rear shocks with OEM KYBs. My local Toyota dealer quoted $1600 for parts alone saying they don't just replace the struts but they change struts, mounts, et al. TIA

 

Yes, all 2G would be the same. You should also replace the top mounts and the rubber pleated boots that cover the top of the struts.

 

Than you Patrick. I would also like to replace my Halogen headlight assembly as the original one are quite dim and unfocussed. Any recommendations on aftermarket brands or should I go for oems? Appreciate your advice