Steering - Pop/Clunk/Knock When Turning Steering Wheel

STEERING
ST001-07

Title:
STEERING INTERMEDIATE SHAFT NOISE

Models:
'07 ES 350

April 25, 2007

Introduction





Some customers may hear a clunk, pop, or knock-type noise when turning the steering wheel left or right. A new intermediate shaft has been developed to address this condition. Use the following repair procedure to remove and replace the steering intermediate shaft.

Applicable Vehicles

^ 2007 model year ES 350 vehicles produced BEFORE the Production Change Effective VIN shown below.





Production Change Information





Parts Information





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.

Repair Procedure

Prior to removing the steering intermediate shaft, make sure the steering wheel and front wheels remain stationary. Once the intermediate shaft is removed, do NOT allow the steering wheel to spin freely.

Ensure the wheels are straight and the steering wheel is centered before removing the steering intermediate shaft by installing a steering wheel holder.





1. Disconnect the steering intermediate shaft.

A. Remove the clamp from the steering column hole shield.

B. Separate the steering column hole cover from the cover boot.





C. Place matchmarks on the steering intermediate shaft and steering gear assembly.

D. Remove the bolt and disconnect the steering intermediate shaft.

2. Remove the steering intermediate shaft.

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. Place the corresponding matchmarks on the NEW steering intermediate shaft. To place the matchmarks on the NEW steering intermediate shaft sub-assembly, place a NEW steering intermediate shaft next to the original steering intermediate shaft (removed in the previous step) and transfer those match marks to the same locations on the NEW steering intermediate shaft.





4. Install the NEW steering intermediate shaft.

A. Align the matchmark with the one on the steering sliding yoke sub-assembly and the steering main shaft assembly.

B. Install the steering sliding yoke sub-assembly with the bolt.

Torque: 35.3 N.m (360 kgf.cm, 26 ft.lbf)





5. Connect the steering intermediate shaft.

A. Align the matchmarks on the steering intermediate shaft and the steering gear assembly.

B. Install the steering intermediate shaft with the bolt.

Torque: 35.3 N.m (360 kgf.cm, 26 ft.lbf)





C. Install the steering column hole cover to the cover boot.

D. Install the clamp to the steering column hole shield.

6. Remove the steering wheel holder from the vehicle (if used).

7. Road test the vehicle to verify the repair and confirm that the steering wheel is centered.