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2006 Sport 2.4 ltr. In 2010 I had the common steering column thump/bump. Dealer changed the steering gear and linkage under an extended warranty and per two TSBs. It's back. Apparently in Toyota's infinite wisdom, they didn't redesign the parts. Just replaced with the same old lousy designed parts. Got a hunch I know the answer but thought I'd throw it out there. Am I stuck with repair costs this second time around or is there some recourse to get them to pay?
 

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This topic has been covered many times, including with a "Sticky" in the static list at the top of this forum.

The search tool is your friend. The first link (post #37 of the "Sticky" thread) may have the best answer to your question, which wouldn't require replacing parts at all:

http://www.rav4world.com/forums/99-4-3-mechanical/91865-how-replace-intermediate-steering-shaft-solve-clunk-problem-4.html#post1766049

Here's another possibility, again not requiring trying to get someone else (e.g. Toyota) to pay for replacing parts:

http://www.rav4world.com/forums/99-4-3-mechanical/191585-even-easier-solution-steering-clunk.html

There is also a reference (with download) to TSB ST001-08 (superseded by T-SB-0318-08 in the download) from Toyota. If you no longer have any kind of extended warranty, maybe you could strong-arm a dealer into fixing it due to the TSB --

http://www.rav4world.com/forums/106-4-3-tsbs/69399-t-sb-0318-08-steering-intermediate-shaft-noise-clunk-pop-knock-10-20-08-a.html


Other related discussions:

http://www.rav4world.com/forums/99-4-3-mechanical/212369-thud-steering-column-cheap-fix.html

http://www.rav4world.com/forums/99-4-3-mechanical/61353-do-you-have-dreaded-steering-knock-popping-sound.html

http://www.rav4world.com/forums/99-4-3-mechanical/88177-steering-shaft-clunk-possible-fix.html

http://www.rav4world.com/forums/99-4-3-mechanical/212009-bump-feeling-steering-wheel.html


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Did this today to solve all my final steering clunks, tried all the other solutions posted......problem finally solved.......no engine removal, no dropping of sub-frame, just support trans axle/motor with 2 bottle jacks and remove the rear mount, had to grind of the studs pressed in mount and replace with bolt-nut combo, now need to get alignment, 4hrs of brutal labor.... but doable without lift. I have the 2.4L 2WD model only, so i'm sure that might be the reason it's doable. was tired, only took a few pics.
 

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