100 Series - Front LCA bump stop hitting hub 'cup' incorrectly, any ideas?

[SMLE]

Hi folks,

2004 100 Series, 4.2TD 1HD-FTE, I posted a thread a little while ago advising that after having everything replaced with OEM parts on the suspension, steering rack, CVs etc front and back, I had a knocking when turning on full lock/close to full lock in both directions and we had been trying to figure it out.

We had a look today and were able to consistently replicate the issue and found that on both sides (front left is worse), the adjustable bump stop which screws in and out of the front LCA is not sitting against the 'cup' on the rear of the hub knuckle correctly when turning hard.

When the hub turns, the small 'cup' on the rear is seemingly too low, meaning the adjustable bump stop on the LCA is hitting the top edge and causing the LCA to move and it's not pretty. We tried adjusting the adjustable bump stop but it didn't alter any of the geometry in this area.

Everything was replaced with brand new OEM, parts were verified against partsouq/Japan4x4, and a local shop near our LC guy sorted the tracking which was showing as perfect after the adjustment there.

Is there something I'm missing here? I couldn't see any reference to anything specific in the FSM which would dictate the heights etc, and there is no front camber adjustment from what I understand either.

A suggestion was made that the lower ball joints could be incorrect or causing the hub to sit too low, but these were as part of the whole assembly straight from Toyota in Japan.

Pics attached showing the contact areas.

Any thoughts/suggestions/prayers gratefully received!

Thanks!

 

[ndg]

Are you doing this with the wheels hanging at full droop or with the weight on the tyres?

I noticed mine doing it in droop when I was bleeding the steering, but don't notice it in normal driving

 

[SMLE]

Are you doing this with the wheels hanging at full droop or with the weight on the tyres?

I noticed mine doing it in droop when I was bleeding the steering, but don't notice it in normal driving

Tried with wheels up, wheels on the floor etc, no difference sadly!

 

[Dirt J]

My first thought was incorrect/damaged balljoints or damage to the spindle.

 

[SMLE]

My first thought was incorrect/damaged balljoints or damage to the spindle.

Thanks!

A suggestion was made that the ball joints (directly fitted by Toyota in the LCA, came as one assembly) could be incorrect, not sure why they would be wrong if it's VIN verified but it's something I'll explore further if there isn't a definite answer

No reason to think the spindles are damaged, but I guess that's also another route to explore too if I don't get any further.

 

[SMLE]

Any other thoughts before I order some ball joints?

Thanks!

 

[ndg]

Doesn't fix your issue, but I reread your first post and you said camber is not adjustable. It definitely is, the upper control arm inner joints have exccentric bolts front and rear to adjust camber and caster.

I can try and get a similar photo to yours to show the alignment of the pin to cup on my rig if that would help?

 

[scubadoober]

What is your caster on that side? Are you getting it aligned?

 

[SMLE]

Doesn't fix your issue, but I reread your first post and you said camber is not adjustable. It definitely is, the upper control arm inner joints have exccentric bolts front and rear to adjust camber and caster.
View attachment 3951697

View attachment 3951698

I can try and get a similar photo to yours to show the alignment of the pin to cup on my rig if that would help?

Yes please!

Very useful, thanks

 

[SMLE]

What is your caster on that side? Are you getting it aligned?

Previously aligned straight after the work done, I didn't get a print out of the alignment but it was very close to where it needed to be from what I was told

 

[ndg]

Here's a photo, normal height

 

[SMLE]

Here's a photo, normal height
View attachment 3953951

Thank you!

Any chance you can measure between these bits so top of ball joint boot area where it sits against the underside of the LCA to where it sits against the top of the hub hole it goes through?

Thanks