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ATTN Kluger owners: Steering Intermediate Shaft Knocking Noise -


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Attention GSU40 GSU45 Owners.

After becoming frustrated with a noise emanating from my steering every time i turned left, reporting it to Toyota the past 2 times its been for service and being told that they couldn't replicate the issue, this time it was just too loud for them to ignore and feel through the steering wheel.

They have finally admitted there is an issue and they have been issued a Technical Newsflash from Toyota Australia (TNF 06/13).

In a nutshell, they wont fix it now, there is no fix to date, they are testing a few things and will have a formal fix.

I personally have driven or been in 3 various Klugers (2009 to 2012 models) and all exhibit this issue.

On a personal satisfaction level, I am very disappointed with Toyota and the fact that the issue has been around since the release of the GSU40/45 series in 2008 and no fix exists.

Please make formal complaint with your dealer, reference this Technical NewsFlash and hopefully one day we will get a fix.

Please post your experiences here if you find a fix or a dealer that is willing to help.

Cheers

Toyota.TNF.06.13.pdf

Edited by phez
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This site is awesome... Our 2009 Kluger Altitude under 28000k have been experiencing the steering knocking noise of late. The knocking is really intermittent and can only be felt while driving through

If this is true and it does work Toyota should be ashamed of themselves. Thanks for posting. Its worth a shot for those who still have trouble.

Hi Connan I found the Customer Service persons at Taren Point, absolutely useless. I suggest that you follow it up at a Toyota Service Centre. Speak to the Service Manager and mention TNF 06

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This is really disappointing. Considering that Toyota's major competition has caught up (and in some cases exceeded) on build quality, Toyota need to recognize that their markets will evaporate if they don't maintain an edge. The Koreans are already selling vehicles of comparative build, and if this is how Toyota are dealing with known technical issues, then it really makes you question them.

My wife's car is due to be upgraded, and we are looking at getting a seven seater. Should I give the Kluger a wide berth?

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We have a 2011 Kluger, it is our first Toyota, Great Car, but the one thing that connects the person to the car, is the steering wheel, so a problem in the steering, seems much magnified over say a knock in another part of the car. For this reason alone, you would think that Toyota would sort this out.

However, a quick internet search of this issue reveals that it has been a reported problem for at least 6 years on different Toyota variants. In some vehicles, it has even been the subject of a recall.

Clearly Toyota are not currently motivated to fix it.

Whilst the problem may not currently be a safety issue, you would wonder at the longer term ramifications of it. Is it possible that there is in fact increased wear on that part? Could this lead to catastrophic failure of that part?

Edited by Nidecker
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Actually I was wrong, looks like from 2003 same part same problem??

https://dl.dropbox.com/u/25027612/TOYOTA%20TECHNICAL%20SERVICE%20BULLETIN%20ST001-06.pdf

https://dl.dropbox.com/u/25027612/TSB_ST003_04%20Steering%20Link%20Shaft%20Noise.pdf%E2%80%8E.pdf

NHTSA Technical Service Bulletin: 10019873 / 00106

Service Bulletin Number: 00106

Replacement Service Bulletin Number: 00106
NHTSA ID #: 10019873

Bulletin Date: Thu, 02/16/2006

Failing Component(s): 013100 STEERING:GEAR BOX:SHAFT SECTOR
Summary: STEERING INTERMEDIATE SHAFT NOISE. *AK
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Very interesting topic for which im following closely been in the market for a new Kluger.With the part that does the actual knock , does anyone have pictures showing one , so we can see what is actually the cause?

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Very interesting topic for which im following closely been in the market for a new Kluger.With the part that does the actual knock , does anyone have pictures showing one , so we can see what is actually the cause?

Down load either doc from my dropbox, and you will see an exploded diagram

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OK thanks for that , yes i see it now .Just curious if the issue gets repaired under "Warranty " , does it still come back anyhow?

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There is an old thread (lost a few pages back) in relation to this issue.

http://au.toyotaownersclub.com/forums/topic/37637-intermediate-steering-shaft/

Sadly this is a common problem and they do not seem to have a fix. See my post below.

My 07 kluger has now clocked nearly 120,000km and the clunk has been with it almost the entire time, other than the short time after they fitted the replacement under warranty. Never let me down though, very reliable. Only other annoyance is the cold weather dash rattles, but really has been very reliable. Most seems good quality, still on the original brake pads and discs, all electronics, trim, paint good, and engine and transmission etc feel like new! So far feels like it would do another 200,000km without breaking a sweat so in no hurry to offload it.

Obviously toyota are not too worried about steering failure from this knock or I am sure there would be a recall.

Posted 25 June 2012 - 10:56 AM

My 2007 model Kluger had the intermediate steering shaft replaced just before the warranty expired back at the end of 2010.
All good until the last couple of weeks when it has started making the dreaded clunking noise on left hand turns yet again. Might explain why the problem is still occuring even in later model Klugers, as it seems even the replacement unit won't fix the issue for good. Does anyone know what happens if you just put up with the clunking issue? Will it eventually fail completely, or is it more just an annoyance? Have been very happy with the kluger over the last 5 years other than this issue and the very annoying cold weather winter dash rattles. (though I am in Canberra so those in warmer climates would never have to worry about the dash rattles, as it isn't an issue in summer here;)
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OK thanks for that , yes i see it now .Just curious if the issue gets repaired under "Warranty " , does it still come back anyhow?

Yep had mine replaced at about 20k or 30k (can't remember) and its been back again from 45k now at 60km and much worse.

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OK thanks for that , yes i see it now .Just curious if the issue gets repaired under "Warranty " , does it still come back anyhow?

Yep had mine replaced at about 20k or 30k (can't remember) and its been back again from 45k now at 60km and much worse.

I had exactly the same experience with my 08 kluger as nidecker. I just recently took it for service after it already being " repaired" under warranty a few years ago for the same clunk to come back ....had the technician come for a drive with me to experience the clunk which he did..... Then basically got told to live with it and if it gets significantly worse come back to us.

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I feel if this noise has been with Kluger's since 2003 , even though it went though upgrades , i cant see the new 2014 model been any different.

Whats the bet that after 15,000kms in the 2014 model , owners start complaining that the steering wheel has the same knock.

I'm hoping of course the issue is solved once and for all , but its just disappointing to read that so many owners have the same problem and Toyota knows about it , but besides an exchange (for temp peace of mind) , it usually returns anyhow.

As some of you are aware , i am in the market to buy one of these Klugers new within the next 3 months or so , but its hard to turn a blind eye to an inherited fault that Toyota cant or don't seem to be too concern about fixing once and for all.

Edited by DDC73
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I feel if this noise has been with Kluger's since 2003 , even though it went though upgrades , i cant see the new 2014 model been any different...........................................................

The point is, it's not just Klugers, but other toyota variants in the mid range size cars? ie camry / rav 4 etc have all be subject of repair / recall etc.

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HI Phez ,

Had my intermediate shaft replaced by caslte hill toyota last year under warranty. Have not had any further issues since replacement . Found the post on this forum regarding the issue.

Regards Silkluger

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  • 2 months later...

I just reported this problem at my 100K service of my 2009 kluger and the service tech noted it in the Toyota system, he said they were expecting some solution around june/july timeframe and that he had about 4 replacement parts sitting in his shop un-approved for install since the tech news flash came out they have stopped replacing them - all they did was confirm it was the same problem and said I have to wait...

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  • 2 weeks later...

This site is awesome... Our 2009 Kluger Altitude under 28000k have been experiencing the steering knocking noise of late. The knocking is really intermittent and can only be felt while driving through steering wheel. This is really disappointing as we traded in our Holden which had some inherent issues from day one bought new from a dealership. Now the Toyota. Hopefully the dealership will address the issue long term wise otherwise my next upgrade will not be another Toyota as we are due to upgrade our second family car.

Has anyone with this issue been addressed recently ? What is the final long term fix from Toyota for this ? Good to know as I will be taking my car in next week to get this issue checked. Will provide feedback once they have looked at the car.

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Hi jay ,I had the clunk in the steering and was fixed about 15months ago and the problem hasnt come back yet ,fingers crossed,they replaced the intermediate shaft,but for some owners the problem comes back after it has been fixed,I read in one of the other posts about this problem on this forum ,that they are finding a permanent fix,and are not replacing anything untill they get to the bottom of whats causing the intermediate shafts clunk,so hopfully the problem be fixed for good.

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Hi jay ,I had the clunk in the steering and was fixed about 15months ago and the problem hasnt come back yet ,fingers crossed,they replaced the intermediate shaft,but for some owners the problem comes back after it has been fixed,I read in one of the other posts about this problem on this forum ,that they are finding a permanent fix,and are not replacing anything untill they get to the bottom of whats causing the intermediate shafts clunk,so hopfully the problem be fixed for good.

Hi Croco,

Cheers for the response. After chatting to the toyota technician he mentioned about lack of grease in steering shaft! based on the original post with TNF outlining greasing and replacing intermediate steering shaft are all short term fixes, do I have the right to reject this proposal to add more grease to steering shaft? Anyway booked in this week for an assessment. Not too sure about printing the TNF as it is copywrited to show the technician what he is proposing is not approved by Toyota HQ.

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I have the same clicking sound while turning left especially out from garage and at low speed. I came to notice this around 70k mileage. Since it was not frequent then, i did not tell dealer on my 70 k service. It got little worse afterwards, then on 80K service, i told dealer. But they said they found no issue during test drive. The clicking became quite frequent and i again told dealer during 90 and100k service, and they agreed then and i believe they greased as per TNF post . It did appear to fix for few days and started again. After i complain, dealer said this is known issue and there has been no formal recall or fix for this. After reading TFN, i was shocked that tpyota is taking too long to give permanent fix even if they know it is a known issue. God forbid... toyota Does not repeat the same mistake as VW did with eventual recall for their gearbox.

Ram

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Little update.... got the car assessed and confirmed the knocking sound is from the steering shaft. Over the last few weeks the knocking can be felt on almost every turn even though it is very subtle. For those who are trying to replicate the knocking noise to dealer try performing a U-turn as this always deliver the annoying knock knock vibrations through steering column on my vehicle.

The dealer was pretty honest ( for a change) and pulled out the same TNF posted with original post on this forum. No apparent long term fix available so the vehicle was logged and once Toyota HQ issues a proper fix they will attend to the issue. I am still flabbergasted toyota makes claim the issue is not a design fault !!! What engineer designs a "knocking " sound in their drive shaft component? let me see the brief that clearly states at design stage stating the drive shaft must emit knocking vibrations during normal function! if the knocking is not part of the design brief then it is a design fault. So far Toyota has still got my repsect for acknowledging the issue and potentially buy another Toyota vehicle but this is wearing thin.

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Yes, I have also reported this knock from my Kluger steering twice with no answer or fix? it does not seem to be affecting the vehicle or handling but a big worry as there may be a very expensive fix later on (AKA out of warranty!) if anyone hears that there is a free warranty fix or modification being offered by Toyota please let everyone know, with thanks

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  • 2 weeks later...

I just got off the phone to my local Toyota service desk. I've had this steering clunk since early on in my 2008 KX-R 2WD Kluger's life (I first reported it at about 30-40k from memory), it's had the shaft replaced once (so they tell me), but at 160,000km the noise is now clearly audible to the front seat passenger.

He says they have recently received a note advising them of an upcoming "field fix", and that since I reported it before the warranty ran out it "should be covered". He also mentioned the word "recall" but I wouldn't bet my house on that just yet.

Despite this issue, and an absolutley useless Bluetooth microphone, I would buy another Kluger without hesitation if this was the type of vehicle that suited my needs. It's been an excellent vehicle overall, it still impresses me with the interior space and comfort considering I only have the base model (optioned with KX-S sound system and 3rd row seats).

Edit: mine does it when turning right, particularly when accelerating at the same time - eg taking off into a roundabout with the wheel partially turned right - I can replicate it every time in this situation. I zip through 9 small roundabouts morning and night on the way to/from work, it will clunk when running straight through just as I accelerate out of the roundabout (ie with the wheel partly turned).

Edited by munster
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  • 2 weeks later...

I just got off the phone to my local Toyota service desk. I've had this steering clunk since early on in my 2008 KX-R 2WD Kluger's life (I first reported it at about 30-40k from memory), it's had the shaft replaced once (so they tell me), but at 160,000km the noise is now clearly audible to the front seat passenger.

He says they have recently received a note advising them of an upcoming "field fix", and that since I reported it before the warranty ran out it "should be covered". He also mentioned the word "recall" but I wouldn't bet my house on that just yet.

Despite this issue, and an absolutley useless Bluetooth microphone, I would buy another Kluger without hesitation if this was the type of vehicle that suited my needs. It's been an excellent vehicle overall, it still impresses me with the interior space and comfort considering I only have the base model (optioned with KX-S sound system and 3rd row seats).

Edit: mine does it when turning right, particularly when accelerating at the same time - eg taking off into a roundabout with the wheel partially turned right - I can replicate it every time in this situation. I zip through 9 small roundabouts morning and night on the way to/from work, it will clunk when running straight through just as I accelerate out of the roundabout (ie with the wheel partly turned).

I find it strange they told you they have just recently received the TNF but his have been out since early this year!

Reporting it during the warranty period is important but I don’t see how they can avoid responsibility since they have released the TNF acknowledging the fault. Let’s hope this get sorted soon as I am getting frustrated over the fact we pay premium for a good vehicle and you get this knocking noise. Surely the steering column is not new tech! Will be looking at getting another car

shortly...another Toyota! The ball is in Toyota’s court let see if they play ball.

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  • 4 weeks later...

I have a 2010 Kluger Altitude 2WD. Over the last 10,000kms or so I have noticed the steering knock at low speed, particularly, but not isolated to, when turning left. I knew nothing about the fact that this was a known problem and simply reported it to the dealer at the 60,000km service last week. I was then told by the dealer that they could do nothing to help me and I needed to contact Toyota Australia direct.

I have done this and was told that Toyota Australia were working on a solution with Toyota Japan but that there was no date set for any resolve. Unhappy with this response, I told them I wanted to escalate the issue as I am due to sell the vehicle later this year, and who wants to buy a car with dodgy steering? Surely this will have an impact on the value of the car? I was then given a case number and was assured that someone would call me back within 48 hrs. That was 3 days ago.

After some research I came across the Toyota Owners Club and quickly realised that this is far from an isolated case, but a worldwide issue. Does anyone have any advice on getting this resolved based on similar experience? I have been singing the praises of this vehicle since I've had it, and was quite prepared to purchase another one, but right now I just feel disgusted at the level of customer service offered by such a well known organisation such as Toyota.

Thanks

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Mine was replaced under warranty, but the problem showed up again I think from memory about 20,000km later. My 2007 Kluger is now coming up to its 130,000km service and the knocking noise/feel has been with it most of the time since I have owned it. Other than that and the cold weather dash rattles it has been a good vehicle. They do not have a fix for this knocking issue sadly though. Obviously (hopefully:) Toyota are confident it will not result in a severe failure. I would hope after their US recall problems, and VW Australia's recent DSG transmission highly publicised dramas, that Toyota have made sure this will not end very badly. PS this issue is well know to RAV4, Aurion etc as well.

Edited by wilsact
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