Steering - Clunk/Pop Noise When Turning Steering Wheel
L-SB-0117-08September 17, 2008
Steering Intermediate Shaft Noise
Service Category
Steering
Section
Steering Gear/Linkage
Market
USA
Applicability
TSIB SUPERSESSION NOTICE
The information contained in this TSIB supersedes TSIB No. ST001-05.
^ Production Change Information has been removed.
^ The Warranty Information, Parts Information, and Repair Procedure sections have been updated to reflect removal, lubrication, and reinstallation of the steering intermediate shaft instead of replacement.
TSIB No. ST001-05 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding.
Introduction
Some customers may hear a clunk, pop, or knock type noise when turning the steering wheel left or right. Use the following procedure to lubricate the intermediate shaft and address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Parts Information
Repair Procedure
Steering Intermediate Shaft Removal
NOTE
Prior to removing the steering intermediate shaft, install a steering wheel holder to ensure that the steering wheel and front wheels remain stationary. Once the intermediate shaft is removed, do NOT allow the steering wheel to spin freely.
1. Disconnect the steering intermediate shaft sub-assembly.
A. Loosen the bolt and remove the clamp from the steering column boot.
B. Separate the steering column hole cover from the boot.
C. Place matchmarks on the steering intermediate shaft sub-assembly and steering gear assembly.
D. Remove the bolt and disconnect the steering intermediate shaft sub-assembly.
2. Remove the steering intermediate shaft sub-assembly.
A. Place matchmarks on the steering sliding yoke sub-assembly and steering main shaft assembly.
B. Remove the bolt and steering sliding yoke sub-assembly from the steering main shaft assembly.
3. Slightly lift the spline shaft upward and expose the splines. Two teeth have been machined down to allow a needle to be inserted to apply the lubricant. Once the missing spline has been located, mark it.
The other machined spline is located 180 degrees from the original.
4. Insert the needle into the shaft and then install the tube of lubricant to the needle.
5. After attaching lubricant to the needle, squeeze the tube to apply grease to the splined portion. All of the grease in the tube should be applied.
6. After applying the grease on one side, remove the needle from the shaft. Place the needle into the shaft on the opposite side (180 degrees from the original location) and add lubricant as performed in step 5.
7. Hold the intermediate shaft from the upper and lower portions and compress and extend about 20 times to ensure that the lubricant is thoroughly distributed inside the splined portion of the intermediate shaft.
NOTE
Make sure that during this process, no foreign objects or material contaminate the grease.
Steering Intermediate Shaft Installation
1. Install the steering intermediate shaft sub-assembly.
A. Align the matchmarks on the steering sliding yoke sub-assembly and the steering main shaft.
B. Install the steering sliding yoke sub-assembly with the bolt.
Torque: 35.3 N*m (360 kgf*cm, 26 ft*lbf)
2. Connect the steering intermediate shaft sub-assembly.
A. Align the matchmarks on the steering intermediate shaft sub-assembly and the steering gear assembly.
B. Install the steering intermediate shaft sub-assembly with the bolt.
Torque: 35.3 Nm (360 kgf*cm, 26 ft*lbf)
C. Install the steering column hole cover to the boot.
D. Connect the clamp to the steering column hole cover boot and tighten the bolt.
3. Road test the vehicle to ensure that the noise is gone.