Some 2005-10 4WD Toyota Tacoma and 2WD Tacoma PreRunner pickup trucks may emit a rattling sound from the steering column when being driven over bumpy roads. One likely cause for the noise, says Toyota, is a defective No. 2 intermediate steering shaft. Replacing the original steering shaft with an upgraded unit, part No. 45220-04020, should eliminate the noise
Start the fix by making sure the front wheels are straight, then install a steering wheel holder to lock the wheel in position. Next, remove the steering column hole cover on the floor by disengaging the four clips. Using a grease pencil, place match marks at the yoke of the No. 2 intermediate shaft where it connects to the steering column, then remove the one bolt and discard it.
Continue by getting the truck on a lift. Now remove the driver's side lower engine cover. Using the grease pencil again, place match marks on the lower splines of the No. 2 intermediate shaft and the coupler. Next, remove the upper bolt connecting the No. 1 intermediate shaft to the No. 2 shaft, loosen the lower bolt, then slide the No. 2 shaft up and out of the vehicle.
Using the illustration, place the new No. 2 intermediate shaft next to the old and transfer the match marks to the new shaft in the exact same locations, as shown. Install the new No. 2 shaft into the vehicle, making sure all the marks align. Install a new bolt to secure the new shaft to the steering column, then tighten all the bolts to 26 ft-lbs. Now reinstall the lower engine cover, lower the vehicle, install the steering column hole cover, remove the steering wheel holder and go on a road test to confirm that the rattling noise is gone.
To complete the fix you'll have to calibrate the yaw rate and steering angle sensors as outlined in a repair manual.
"Factory Fixes" is written by Jim DePalma, a 30-year veteran of the auto repair business who has served stints as a service manager, parts manager and ASE-certified technician. His column provides vehicle manufacturers' authentic factory technical service bulletins (TSBs) that have been condensed for easier reading. Mr. DePalma advises that techs always check with a dealer or repair information system for the latest revisions before starting to work on a vehicle. He can be reached via e-mail at [email protected].