Steering Pinion Shaft problems of the 2007 Toyota RAV4

At 51,000 miles, there is a heavy rattle in the front end when driving on rough roads. After replacing several parts, local mechanics now tell me that the rack and pinion steering gear needs replacement. This does not seem to be the intermediate steering shaft problem that is the subject of Toyota service bulletin #t-sb-0319-08. I do not feel anything abnormal in the steering wheel, steering is smooth and the problem is not noticeable driving on smooth road surfaces. The noise seems to be getting worse with time, so I am concerned that the steering could fail altogether.

My 2007 Toyota Rav4 has a "clunking/popping" noise coming from what appears to be the steering linkage somewhere between the intermediate shaft and rack-and-pinion assembly. In early 2014, a Toyota dealership in indiana recommended servicing the intermediate shaft assembly via an issued Toyota service bulletin. The intermediate shaft was replaced replaced in the spring of 2014 (cost=$1000, car mileage ~65k). I have since job relocated to new jersey and the problem has resurfaced (car mileage ~75k). A dealership here told me that the rack-and-pinion assembly needs to be replace (est. Cost= $2000). General signs of rack-and-pinion failure as stated by the dealership and general research are not observed in my car (signs including "play/slop" in the steering wheel, loose steering, stiff steering, etc. ). Further research of this issue has show multiple hundreds-of-thousands of Rav4 owners inquiring about this issue either via Rav4/Toyota forums, or through the NHTSA and other third party auto safety agencies. The dealerships seem to be guessing at what the problem is, and they issue repair guidelines based only on service bulletins without fully investigating the issue. There is a serious safety concern with a "clunking/popping" noise with the steering assembly of these automobiles. Owners of this (highly rated, abundantly sold) Rav4 model should be issued a recall by Toyota to have the rack-and-pinion and the intermediate shaft assembly fixed without consumer purchase. Toyota is aware of the problems, as they have issued multiple service bulletins, but have yet to deem the issue a safety concern leaving their loyal owners with repair cost in upwards of $3000 for cars that are well under 100,000 miles, but outside of Toyota's warranty period. Protecting the safety of drivers and their precious passengers, should be the number one concern of Toyota and the NHTSA.

My 2007 Toyota Rav4 has developed a loud clunk and slight binding when the steering when turning at slow speeds. The diagnosis from Toyota appears to be a worn intermediate steering shaft. In my opinion, the steering shaft on this vehicle does not resemble those on other cars in that starts connected to the steering wheel and then runs vertically down through the dash area changing direction abruptly. Other vehicles have a generally straight steering shaft in line with the steering wheel axis and no abrupt changes in alignment. There appears to be significant discussions on Toyota related websites of similar Rav4 steering shaft problems. Is Toyota and the NHTSA aware of this problem and preparing an investigation or remedy.

Steering has play and clunk at times causing car to swerve do mechanical defect and/or over correction of the driver do to sensation of loss of steering control. After reading user forms on this vehicle it is common to the vehicle and should be recalled by Toyota to prevent fatal accidents. Recall items should include middle shaft and rack and pinion. . Read more...

This is a follow-up to complaint number 10322423 I filed on March 26, 2010. At 37,109 miles my 2007 Toyota Rav4 had a binding and thumping noise in the steering column. I took the vehicle into the dealership where it was purchased and was informed the intermediate steering shaft needed to be replaced, but it was not a safety issue. At 46,781 miles I took my vehicle in for an oil change at my local automotive repair facility (not a Toyota dealer). They recommended I have Toyota look at the vehicle since the power steering rack and pinion was bad. I took the Rav4 to a different Toyota dealer in the area. They confirmed the power steering rack and pinion needed to be replaced. I asked them to replace the intermediate shaft while they were working on the vehicle’s steering system. A few days prior to the rack and pinion being replaced, the car felt like it had no power steering and it was difficult to turn the steering wheel. The power steering rack and pinion was replaced at 48,555. The second Toyota dealership informed me the intermediate shaft did not have to be replaced because the binding and thumping noise was being caused by the power steering rack and pinion. I do not have the binding and thumping noise in the steering since the power steering rack and pinion was replaced. Toyota has issued two technical service bulletins (tsbs) for the binding and thumping noise in the steering column – replacement of the intermediate steering shafts. The problem I had with the binding and thumping in the steering column was caused by the power steering rack and pinion, not the intermediate shafts. The power steering rack and pinion probably was bad at 37,109 miles. Many 2006-2008 Rav4s have reported problems with the steering columns. Does Toyota really know what’s causing the steering column problems on the 2006-2008 Rav4s? it’s very disappointing Toyota and the NHTSA does not consider a steering problem a serious enough problem for a recall.