Four problems related to steering column have been reported for the 2004 Toyota Highlander. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Toyota Highlander based on all problems reported for the 2004 Highlander.
Highlander recently received 30k service at Toyota dealer. Car mileage was approximately 29k. The service advisor reported that the intermediate shaft in the steering column was making a clunk type sound and should be replaced. He believed Highlanders and tacoma's had been having a problem. He did not think the part would break but that the part had been redesigned and will need to be replaced.
Bout my 2004 Highlander 3 months ago, used, with 46k miles on it. I took it to my mechanic last week to get the oil changed and tires rotated. He took it for a drive and said that it won't pass inspection in 3 months because of the steering. There is a clunk in the steering, which I never thought was abnormal but he said it is. He also said there is a service bulletin out on it. I called the dealer and made an appointment for next week. I seriously had better not have to pay for this.
Noisy steering shaft caused me to take car to dealership, where I was told the shaft was 'worn' (tiny bearings within the shaft were worn) and the shaft was replaced. Dealer informed me they'd seen this problem on other Toyota Highlanders, and on their economy Toyota prisms as well, but manufacturer had not issued any recalls. I paid the bill using my extended warranty.
Steering shaft on the 2004 Toyota Highlander did not feel safe, felt loose and noisy when turning. Toyota refusesd to fix the problem under warranty, a TSB was issued in January 2006, which indicated Toyota's awareness of the problem, but did not want to publicly admit it. While driving it felt like the steering column coud break off, and if that happened, it could have caused many deaths.