I am having this same issue - you described it perfectly. Like an old computer working hard. Mine seems to be happening over 40 MPH under normal driving conditions. Hope to get to the bottom of it soon as it is really annoying.
I just had this exact same failure this past weekend on my 2004 V6 Sport Edition. Time to drill out a bolt, tap, and repair! I was doing some pretty aggressive off-roading over large boulders in Massachusetts.
I loosened the two bolts but had a hard time getting the assembly to slide up the shaft. I tapped with a hammer and tried with a pry bar but it didn't seem like I was making progress...AND THEN...
I gave up thinking I'd try another day. I jumped in my truck and drove around. The rattle is gone...
I just mounted up 255 80 17 KM2's on FJ Steelies for my 2004 4Runner SE this morning. They are sweet! I am a big fan over my old 285's...my power steering is much less strained now.
Burzon's Overland Adventure Continues: 2004 4Runner SE (V6) Build - Page 5 - Expedition Portal
I just mounted up some 255 80 17 KM2's on refinished FJ Steelies on my 2004 4Runner this morning. Very pleased so far but have not had it on the trails yet.
Burzon's Overland Adventure Continues: 2004 4Runner SE (V6) Build - Page 5 - Expedition Portal
