Very interested in a solution. My 2011 LC200 seems to be developing this.
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I fixed the clunk in my steering wheel. My hypothesis above about slip joints was wrong, but the general idea about the problem lying outside the column was correct.
So I basically replaced everything that lies between the steering column and the steering rack. This includes both intermediate shafts and the grommet/bushing/boot (Toyota calls it a coupling shield) where they enter the firewall. Parts 6, 7, 8 on the diagram.
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The job was not difficult. The hardest part was trying to remove the fender well splash guard without breaking the clips (failed).
It turns out both intermediate shafts felt and functioned like the new parts when held in hand. Only the upper (#1) intermediate shaft has a slip joint on it. The #2 intermediate shaft has a metal bellows on it, but my guess is that the bellows is designed to collapse in a crash. So the problem PROBABLY did not lie in either of the intermediate shafts.
However, the coupling shield (rubber boot on the firewall) was torn around its circumference where it holds the intermediate shaft. It's actually fairly thick, with double-wall construction and a circle of thick foam to reinforce it. Mine was torn on the engine compartment side. I'm guessing it is designed to control some of the bounce or vibration in the shaft when going over bumps, so the damage probably allowed too much movement in the shaft.
Total cost for all the parts was about $325 shipped to my door in 2 business days from Partsouq. The coupler shield by itself was less than $40 before shipping. Could have been a very cheap fix, but I wasn't sure which part was the culprit.
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As noted earlier in this thread, I had a clunk in my steering wheel that was caused by a torn rubber boot on the steering shaft at the firewall.
Fixing that took care of the vast majority of the noise. But over the past year I've noticed some residual noise in the column when going over bumps. Eventually, I got tired of hearing it, so I removed the steering column completely from the vehicle to inspect it. That process is actually much easier than you would think.
At least on the 2010 model, removing the steering shafts does not require any involvement of the steering column. All you do is disconnect the single bolt that holds the upper intermediate shaft to the steering column shaft. Then the intermediate shaft has enough slip in it that you can side the upper end off the steering column shaft. (Match marks on everything and tying the steering wheel securely in position are important to remember.)
Then you would remove the bolt that holds the upper intermediate shaft to the lower intermediate shaft. This bolt is on the engine compartment side of the shaft. When that bolt is free, you can just completely remove the upper intermediate shaft via the cabin side. It will slide out of the rubber boot on the firewall and into the footwell. To replace that rubber boot, only the upper shaft needs to be removed.
But to answer your actual question, to remove the steering column, you remove the horn pad, airbag, steering wheel, and the upper and lower steering column plastic trim pieces. I didn't need a steering wheel puller on mine; it came off fairly easily. Tape the clock spring in place so it does not rotate. Then you will remove the under-dash trim panel, the lower dash trim around the knee airbag, and then remove the knee airbag (4 bolts, remove the metal frame holding the airbag rather than the actual airbag itself). At this point there will be about 10 different electrical connectors between the clock spring, steering angle sensor, and the motors/solenoids on the steering column. They're all easy to reach and easy to remember where they go back. Then disconnect the push clip that holds the heater vent to the steering column and the plastic clip that holds the wiring harness to the steering column. Remove the bolt that holds the steering column to the upper intermediate shaft, and remove the 4 nuts that hold the steering column to the body. Don't forget match marks on the steering wheel and steering shafts as you go.
FSM tells you to remove the heater vent tube and other parts of the dash, but that is not necessary. Everything is fairly visually intuitive, aside from the initial step of removing the horn pad and pulling up on the little yellow tabs on the airbag connectors.
Takes an hour the first time you do it, but would only take a half hour once you are familiar with the process.
I know I'm 3 years late on this thread, but I just have to say thank you!! Your hypothesis was absolutely correct. My steering column rattle was about to drive me insane, especially after replacing my sway bar end links and bushings last week with no resolution. I just telescoped the wheel in/out 10 times and it's completely gone! The steering is smoother and feels properly lubricated now with no more rattle. I'm still in disbelief. I have a 2008 with 213k miles if that's helpful to anyone. Thanks again!As noted earlier in this thread, I had a clunk in my steering wheel that was caused by a torn rubber boot on the steering shaft at the firewall.
Fixing that took care of the vast majority of the noise. But over the past year I've noticed some residual noise in the column when going over bumps. Eventually, I got tired of hearing it, so I removed the steering column completely from the vehicle to inspect it. That process is actually much easier than you would think.
Getting it on the bench, there were only 2 ways I could get it to make any noise. The first was rotating the shaft against the steering lock pawl. This made a loud click, but this really should have zero chance of making noise when driving down the road. I used a zip tie to push some grease into the pawl area anyway.
The other way to make noise was to force the shaft up and down perpendicular to it's axis. There was a tiny, tiny amount of play up and down, with zero play left/right. The noise seemed to come from where the telescoping shaft pieces fit together up inside the column. I hoped to pull those two shafts completely apart and regrease them, but I did not have the courage to get very aggressive with it.
Anyway, I put it all back on the truck and then cycled the telescoping steering (not the tilt) through its full range of motion about 5 times. The noise with bumps is now totally gone.
My hypothesis is that the normal vibration of the steering shaft over time causes the grease in the telescoping shaft to be redistributed in a way that allows the half shafts to click together. Cycling the telescope function may help move the grease around a little.
TLDR - If you have a steering wheel rattle over bumps, try cycling the telescoping function all the way in and out several times. It costs nothing, takes 15 seconds, and may help. This may apply mostly to those of us who have disabled the auto-retracting wheel feature.
Hey Heff, I'm having the same steering clunking issue with my 2008 LC. Sorry if this is a stupid question but how did you telescope the wheel in and out? By starting the engine numerous times? Thanks in advance!I know I'm 3 years late on this thread, but I just have to say thank you!! Your hypothesis was absolutely correct. My steering column rattle was about to drive me insane, especially after replacing my sway bar end links and bushings last week with no resolution. I just telescoped the wheel in/out 10 times and it's completely gone! The steering is smoother and feels properly lubricated now with no more rattle. I'm still in disbelief. I have a 2008 with 213k miles if that's helpful to anyone. Thanks again!
There is a small adjustment knob/joy-stick on the left-hand side on the steering column behind your steering wheel. Aproximately at 7 o'clock when you're looking at your steering wheel. That 4-way knob moves the steering wheel position. You're looking for the in/out motion, not the up/down one, with 5-10 full in/out cycles.Hey Heff, I'm having the same steering clunking issue with my 2008 LC. Sorry if this is a stupid question but how did you telescope the wheel in and out? By starting the engine numerous times? Thanks in advance!
Thanks very much for the response! I'll give that a tryThere is a small adjustment knob/joy-stick on the left-hand side on the steering column behind your steering wheel. Aproximately at 7 o'clock when you're looking at your steering wheel. That 4-way knob moves the steering wheel position. You're looking for the in/out motion, not the up/down one, with 5-10 full in/out cycles.