ATTN Kluger owners: Steering Intermediate Shaft Knocking Noise -

[2011kluger]

I just got my car back from the dealer after replacing the iss. The steering seems tight and there is no knock. I hope this will be the end.

I cant complain about the dealer as when I mentioned to them that there is a knock in the steering they agreed that there is a problem with the steering and booked my car in for the replacement.

[Mira]

If you all have the same problem, or had it, it is really important that you report it to the Department of Infrastructure and Regional Development:

https://www.infrastr...submission.aspx

The department will only investigate if there is a recurring issue and if it is a safety concern, they will refer it to the ACCC and issue a recall.

[Milo 10]

Hi all,

I'm pretty sure that my 2010 Kluger KXS AWD has the same problem. Knocking noise coming from the front part of the car.

Must be the intermediate steering shaft.

Is there a definitive, permanent fix for this problem?

As the car is out of warranty, would Toyota fix the problem free of charge or would I have to pay for this known issue?

Thanks

Milo

[waz2068]

I had my intermediate shaft replaced sometime ago. Thus far I'm pleased to say it hasn't reoccurred. So far so good. I would have travelled in excess of 20,000 klms since done. Hope this helps.

[pinot52]

Hi Milo

It should be replaced at NO cost to you.

Try your regular dealer first, if no satisfaction, then go to somewhere like Sydney City Toyota. Talk to the service manager. They are fully aware of the problem.

There is now a FIX for the issue.

My Kluger was built with a faulty ISS. It was replaced 3 times before 10,000 k's. Finally the last one seemed to be the correct part and appears to have fixed the issue.

Read up on some of the earlier posts.

Let us know how you go.

[Milo 10]

Hi all,

Rang Peter Warren. They said to bring it in for a free test drive and they could probably get Toyota to

pay for half the repair cost. Rang Sydney City Toyota. They want $140 to assess the problem, but my

chances of getting the repairs covered by Toyota are unknown.

Took the car to my mechanic first, but the clunk did not appear, as expected, as the clunk doesn't happen

too frequently. They lifted the car, inspected everything underneath, but no problems were evident.

Since taking the car to my mechanic, the car barely ever makes the clunk now! The steering mechanism

must have "stretched" while being lifted on the hoist at the mechanic's.

We'll see how it goes.

Edited March 31, 2015 by Milo 10

[merlindie]

Hi - I just purchased a 2010 KXS Kluger second hand from a private owner last month. I have only just started noticing the knock in my steering wheel while turning left. I am due for my 50000 km service and ill be taking it to the same Toyota dealer where the previous owner got it serviced. Is this something I can expect them to repair without a cost to me? Is there anything I should be mentioning to them?

Thanks for your help - this is my first Kluger and really happy I found this forum.

[Aussie Camry]

Hi all,

Rang Peter Warren. They said to bring it in for a free test drive and they could probably get Toyota to

pay for half the repair cost. Rang Sydney City Toyota. They want $140 to assess the problem, but my

chances of getting the repairs covered by Toyota are unknown.

Took the car to my mechanic first, but the clunk did not appear, as expected, as the clunk doesn't happen

too frequently. They lifted the car, inspected everything underneath, but no problems were evident.

Since taking the car to my mechanic, the car barely ever makes the clunk now! The steering mechanism

must have "stretched" while being lifted on the hoist at the mechanic's.

We'll see how it goes.

This happened on my Camry Sportivo it was lifted on a hoist looked around checked bolts were tight etc put down drove around all week and never heard or felt it again.

Edited April 20, 2015 by Aussie Kluger 09

[TLong]

Hey everyone,

This issue has been solved in the US by a Rav4 owner and it works on a Kluger.

I did it yesterday and I can verify 100% that it has solved the steering clunk issue

in my 2011 Kluger.

I bought WD40 Specialist Wet PTFE lubricant from Bunnings and diabetic syringes from a

local chemist.

I have little to no experience working with cars, so don't think this is difficult. It isn't.

Be warned that he goes on a rant about religion right at the end.

[waz2068]

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.

Edited May 13, 2015 by waz2068

[DDC73]

Thanks for sharing , i have a 2013 model and sorta been waiting for the clunk to happen to me ,now that ive seen this i will give it a try myself when required :)

[TLong]

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 Warren,

I agree. Toyota told me it would cost almost $1000 to get the new shaft installed.

A mechanic brought this to my attention. I thought it would be worth a shot as

he suggested that the steering systems between the Kluger/Highlander

and Rav4 would be very similar.

He was right.

The only question is will this need to be done frequently.

The guy in the video said he had driven 6000 miles (not km's) and hadn't had the issue

reoccur.

Even if it needs it every 3 months, it takes 10 minutes and cost me $20 for the oil and 10 needles.

That would last me 2.5 years at that pace. Not bad for $20!

[pinot52]

Before doing anything, please go back to the very first post by 'phez'. Take this report number with you when you go to the dealer. Also read some of my earlier posts.

The ISS issue is a TOYOTA build problem. They now appear to have a FIX for it, and it should be done for FREE, no matter how old the vehicle is.

Mine was finally fixed after two failed attempts. With less than 10,000 k's on the clock I was onto my 4th ISS.

As much as the video from the USA was interesting, I would not think it is a long term fix. I would not even consider doing it when Toyota should be replacing the faulty shaft with a new one.

If the dealer wants to charge you, tell them you are going to ACCC with a copy of the Report.

Toyota have buried their heads in the sand over this and will try and fob you off.

In most cases the KLUNK is intermittent and might not show up when the service person takes it for a test drive. You just need to jump up and down and make some noises.

It is pointless going to Toyota Australia Customer service as they are absolutely useless.

John

[Aussie Camry]

Very simple remedy but would you not want to get grease in there instead of oil ?

[teddy1386]

Ive got a 2012 kluger and ive experienced the clunk. I had 1 month warranty left and i booked it into canterbury toyota who did a test drive and acknowledge the issue. I just mentioned that i know of a friend who had the same issue and had the steering intermediate shaft replaced and it fixed the problem. They disagnosed it and came back concluded it was that and waited 2 week for a part from japan which is a permanent fix of the known issue.

Have got the car done and it hasnt made a noise since.

Hope this helps others out in the future who look to get the clunking noise rectified.

[Mr Lee]

Before doing anything, please go back to the very first post by 'phez'. Take this report number with you when you go to the dealer. Also read some of my earlier posts.

The ISS issue is a TOYOTA build problem. They now appear to have a FIX for it, and it should be done for FREE, no matter how old the vehicle is.

Mine was finally fixed after two failed attempts. With less than 10,000 k's on the clock I was onto my 4th ISS.

As much as the video from the USA was interesting, I would not think it is a long term fix. I would not even consider doing it when Toyota should be replacing the faulty shaft with a new one.

If the dealer wants to charge you, tell them you are going to ACCC with a copy of the Report.

Toyota have buried their heads in the sand over this and will try and fob you off.

In most cases the KLUNK is intermittent and might not show up when the service person takes it for a test drive. You just need to jump up and down and make some noises.

It is pointless going to Toyota Australia Customer service as they are absolutely useless.

John

Where do I download the doc from?

[pinot52]

Looks like the Technical News Flash TNF 06/13 issued by Toyota Australia and was in the first posting has been deleted.

When you contact the dealer ask them to refer to TNF 06/13 issued by Toyota for the Kluger.

I do have a copy of it, but was threatened legal action by the totally 'incompetent nutters' (a polite statement) at Toyota Australia in Taren Point if I was to reproduce it. This was part of an email sent to me by Toyota:

"We respectfully advise that the Toyota document (TNF 06/13) carries a copyright clause which states that this material may not be reproduced or copied, in whole or part, without the written permission of Toyota Motor Corporation."

All dealers have a copy on file.

This is the main reference:

Date: 14/01/2013
Ref No: TNF 06/13
Model: Kluger GSU40/45
Subject: Steering Intermediate Shaft Knocking Noise

Best of luck. Note, it should be fixed free of charge, if not contact ACCC

John

[Mr Lee]

Hi All,

So I took my car to the dealer who had it inspected under TNF 06/13. They confirmed that the issue to be the intermediate steering shaft.

The dealer requested repair approval for costs from Toyota; the response was that they will pay $200 of the $800 cost to repair due to vehicle mileage.

I have driven some really old vehicles in my day (with several other issues) but never a steering noise like this. I am pursuing this further.

...And to think I was considering buying the new Fortuner ... Catch a wake up Toyota!

../edited .. corrected spelling and grammar

Edited November 9, 2015 by MrLee

[pinot52]

Hi Mervin

As mentioned previously you should not have to pay for this, no matter how many k's are on the car. There is more than enough evidence to prove that Toyota built and sold these cars with a 'dodgy' ISS. My brand new Kluger starting making noises on the way home after I picked it up. The Service manager from Fergusons Toyota Hurstville told me it was nothing and that I was not used to driving such a vehicle ..... Total BS. Before 10,000 k's it was replaced three times (at no cost to me) until they got it right.

If the dealer insists on charging you, I suggest you tell them you will contact The ACCC.

John

[Mr Lee]

So I told them that will contact the ACCC and they basically told me where to shove it !

It's wrong that companies like these can get away with covering issues in Australia

[jimmymak]

After I have read this post and it made me realised that clunking noise is something abnormal.

So I booked in the warranty check with Toyota Pakenham and the tech guy went in a drive with me and confirmed the noise from steering shaft.

The service manager reckon it may not be part of the warranty claim at the beginning.

Next day, he has rung me and advised me that it is all good and approved, cost me nothing to replace, good news without the need to harass them that I will contact ACCC.

Therefore, anybody experienced the same issue, i strongly recommend you to contact your dealership and sort this out...maybe toyota australia might change and starts to roll out new policy to change all steeting shaft problem if any users raised their issues.

[Mr Lee]

@jimmymak,

What km's has your Kluger done? Is it still under warranty?

This clunk is too annoying and still don't feel it's fair to pay $$ for a lack of quality issue

Cheers

[pinot52]

Jimmy

You should not have to pay for this 'FIX'.

Suggest to try another Toyota Service Centre and if no luck, then contact Toyota Australia.

Everybody that I know who had the issue had it fixed at NO COST.

Toyota Japan and Australia have know about this issue for years and from the looks of things kept selling the cars.

John

[Mr Lee]

Hi John,

The dealer gave me the warranty prior approval number which I used to contact Toyota Australia, they refused to pay for the entire repair due to the km's.

I just emailed the same dealer now for the cost in writing. I am going to try emailing another dealer to check the result.

I wanna keep the Kluger as it is still a good family car but want to sort out the niggly's:

* Steering Clunk

* Transfer Case Whine

* Rack Ends

* Shock Abosrbers (Maybe)

* and finally new tyres

Then I'm good for a number of years

Lee

[pinot52]

Interesting. I was not aware that it was an issue related to km's. From all that you read, the cars were built with a faulty ISS and that should be the end of the story.

My new Kluger klunked as I drove it out of the dealership on day one. I was not aware of the issue. In the end the ISS was replaced 3 times (at no cost) until they finally fixed it. At one point they did talk about charging me. I jumped up and down and they fixed it.

It is disappointing that Toyota are wanting to charge you for it. Believe me, Toyota Australia sadly lacks in Customer Service skills.

Knowing that Toyota reads these postings, I say to them, "get of your lazy backsides" and fix these vehicles.