Drive shaft noise or U joint noise (LEXUS 4/06 TSB page 18) aka Driveshaft thump/bump

[Climb14er]

He was certainly doing what he believed would work, it makes sense and it's a proven procedure.

The drive line clunk is an example of a very bad Toyota design! No getting around that. Just another example, unfortunately, of the factory just not paying attention.

As most are well aware, the factory has known about this for many years in the 4th generation. They gave me the poppycock reasoning that they could 'fix' the Lexus' same system/problem but not the 4Runners because 'they use different parts'.

That was one lame excuse!

The reason why they have not addressed this issue (once again) is that the Lexus 4WD costs 25K or more... than the 4Runner. There's more profit in the Lexus than the 4Runner and there are probably more 4Runners out there with the same problem and they don't want to do a recall.

For the record, my good friend's Highlander Hybrid... has a 'worse' clunk than my 4Runner.

This is one reason that I'm extremely reluctant to buy the 2010 redesigned 4Runner. The main reason is that they did away with the Torsen system, there's no V8 and it appears as if the factory designers are under pressure to continue to cut costs like a samurai financial accountant... slashing with no regard at all to the consumer at all.

 

[fstgtx]

I recently bought a left over 4Runner brandnew. I now have 6500 miles and I recently starting having the "Clunking" Took it to the dealer today and of course they could not make it "clunk." BUT they were quick to say that some clunking noise is normal. I guess they will be seeing me alot.

 

['04-Sport]

Hello - new guy here with the same or similar problem.

My 2004 V8 4WD Sport Edition has just over 91K miles and I have begun experiencing the "clunk" nearly full-time lately. Here are some facts:

Had a collision affecting the right front corner two years ago - repair done by a Toyota shop with a stellar reputation. No problems.

Have been servicing the 4Runner at another Toyota dealer nearer my home for about 18-24 months - never a problem until now. After the 90K service that included the timing belt, plugs, tranny flush and radiator flush, I started to hear a "tinny" metallic sound when accelerating, braking, hitting bumps and making slow tight turns. Took the car back to the dealer because I thought something was installed incorrectly or... The tech dropped the skid plate and found (according to him) that the lower control arm bolts on the right side were somewhat loose. After he tightened them we went for a test ride and the clunk was gone. The tech then re-installed the skid plate and I drove home - the "clunk" had returned.

Went back to the dealer and commented about the return of the noise - the tech then found other things that were loose - a bracket on the right side and the a/c condenser - tightened them up but the noise remained. I continued to mention that the noise was gone when the skid plate was off but the service adviser kept telling me that the skid plate cannot be the problem. Anyway, they then pointed out that a weld on the bracket connecting the frame to the metal plate that is behind the "cosmetic" bumper on the right side was not done correctly, leaving a gap between one small corner area of the two surfaces. They claim that the noise is a result of that bad weld and the shop that did the body repair is at fault. That, combined with all of the loose stuff they found (that they never found before and that I never noticed before) leads me to believe that this shop has been jerking me around, trying to blame another dealer's body shop, because they don't have a clue.

Any suggestions?

 

[Climb14er]

I recently bought a left over 4Runner brandnew. I now have 6500 miles and I recently starting having the "Clunking" Took it to the dealer today and of course they could not make it "clunk." BUT they were quick to say that some clunking noise is normal. I guess they will be seeing me alot.

Do you plan on taking the 4Runner with the clunk back to the dealer numerous times? For what reason?

Many of us have been through this route and the same answer always comes back: 'it's normal'.

It's your time and frustration level but FWIW, forget-about-it, Toyota really doesn't care nor will they do anything. Then again, YMMV so good luck to you where many others have walked away shaking their heads. :redbrick:

 

[d_cool]

I used green grease

I used green grease and so far its been better than what I used before. not a fix but will prevent the heart attack...

 

[Iowa4Runner]

We're close to buying a new Highlander for my wife IF the dealership will provide a real fix for my '04 4Runner clunk problem. I could hand the service manager the Lexus TSB but he'd probably have no idea what to do with it.

My dealer wouldn't do squat about my thumpy 4Runner, so I stuck to my guns and told them I wouldn't be buying another vehicle with a fake warranty. No Highlander for me!

Are you listening Toyota??? You just lost a sale.

 

[chaz]

some have also reported that after installing theyre lift, the noise (thump) has gone away. i know mine did, but i still get it lubed once every year.

 

[Iowa4Runner]

i did the lexus tsb problem seems to be solved
the shaft about $250 bucks if you just want to buy it

Did you replace just the drive shaft or did you replace all the items addressed in the Lexus TSB?

I took my driveshaft apart, cleaned it, greased it and reassembled. The clunk came back almost immediately, although it's not quite as harsh as it was before. I need to find a real fix.

These splines don't look so good...

 

[BROOKLYN]

Did you replace just the drive shaft or did you replace all the items addressed in the Lexus TSB?

I took my driveshaft apart, cleaned it, greased it and reassembled. The clunk came back almost immediately, although it's not quite as harsh as it was before. I need to find a real fix.

These splines don't look so good...

just the driveshaft nothing else

 

[Gofficer]

I was experincing the same thing with my 03 4-runner sport. I give the whole drive line a grease every time I do an oil change. When you look under neath where the drive shafts meet, you will see grease on the under side of the vehicle. Well at least with mine there is. I believe the seal between the two drive shafts does not seal all that well and the grease adventualy works it way out.
Toyota had no answers for me on this problem.

 

[claydoctor]

My 2006 Sport now has over 100K miles and is therefore past any warranty. The last time I complained about the clunk, I was told that the driveshaft needed routine greasing and that Toyota considered it a "maintenance" issue, which meant that once it was out of warranty, greasing would be on my dime.

 

[00328]

I was experincing the same thing with my 03 4-runner sport. I give the whole drive line a grease every time I do an oil change. When you look under neath where the drive shafts meet, you will see grease on the under side of the vehicle. Well at least with mine there is. I believe the seal between the two drive shafts does not seal all that well and the grease adventualy works it way out.
Toyota had no answers for me on this problem.

I keep mine greased pretty good too. I also have a 'grease line' underneath where the front ujoint is. I think it's just from overloading the fittings with grease and as the ujoint spins it gets thrown on the under carriage.

 

[Iowa4Runner]

Unfortunately no amount of greasing in the world will fix Toyota's mistake. All you can do is hide the problem by packing the joint so full of grease that it won't slide anymore. But that can lead to much bigger problems.

Thank you Toyota for turning your backs on us. F*&^ing weasels...

 

[fstgtx]

I just was at the dealer again for another issue. For some reason they cant ever seem to " RE CREATE" the same issue. This was for wind leak. So the clown at the counter tells me my truck is done and they could not re create the problem. I roll my eyes and said "AGAIN". He said I'll get the tech to go for a ride with you. The tech goes with me and not more than 20 seconds into the ride he wants to go back to the shop.He said he didnt hear anything. I clearly heard the wind noise. He says, " I DONT HEAR IT." After a short agrument he tells me he will replace the seal on the door. So while he is in the truck I ask him about the " CLUNKING." He said OH YA WE GET ALOT OF THOSE THE YOKE STICKS. I ask him if there is anything kind of tsb out. He said no but we fix those all the time. The splines rust and we need to take the drive shaft out and grease it. It not a big deal. I told him it sure doesnt seem like something that should be greased constantly. He said we do it all the time.

 

[RickyCRX]

Some things are pretty obvious here....

a) It doesn't cause any damage or long-term durability/reliability issues
b) Toyota won't do anything about it

Why waste so much energy complaining about it?? My 4Runner even does it on occasion, and I don't even HAVE a driveshaft with grease fittings. (Yes, my 2WD 4Runner occasionally has a driveline 'clunk' when letting off the brake pedal after coming to a stop. Live with it.

Seriously -- this thread is 44 pages long at this point... Is it really worth whining about it any more?

 

[MrTom]

I ask him if there is anything kind of tsb out. He said no but we fix those all the time. The splines rust and we need to take the drive shaft out and grease it. It not a big deal. I told him it sure doesnt seem like something that should be greased constantly. He said we do it all the time.

Bull: My 03' started clunking on the way home the day I took delivery of the new vehicle(3miles on od). A Customer Service Rep came to visit me after many letters and calls of complaint regarding the issue. Her brand new 4Runner had the exact same issue. Was told that Toyota considers it a "normal operating" issue and nothing would be done as it does not cause any negative mechanical problems.
Apparently Jeep and GM has had the same issue in its 4x4 vehicles but it does not seem to occur in AWD vehicles like Subaru.
Lexus has issued at least 3 TSB's for the GX and the problem has never been completely resolved. Will be interesting to see what arises in the new 2010 GX-460
..................

 

[scottm]

Apparently Jeep and GM has had the same issue in its 4x4 vehicles but it does not seem to occur in AWD vehicles like Subaru.

AWD cars like Subaru have stationary rear differentials with half-shafts and CV joints going out to the rear wheels. So the driveshafts don't move or telescope, and the rear wheels are on independent strut suspension, completely different, and not as rugged.

My truck is a truck, it has some noises, but no clunk I've noticed in my two weeks of ownership. It would have to be a pretty significant clunk for me to worry about it. If this were a car with independent rear suspension, I'd be very concerned about a clunk, something in the suspension would definitely be wrong. But I bought a truck.

 

[BIGBLACKV8]

Hey guys,

I just bought a 04' 4Runner 4wd, love the truck BUT, last night I felt the thump and then my truck was in "limp" mode. It was as if I had 50 horsepower. And it would barely shift gears, also when the rpm was getting up there it sounded like a supercharger ( that whining noise). This all lasted for 15 minutes i was driving, I then parked it and let it sit for 10-15 minutes. When I started it back up, it was back to normal.

Anyone else experience or heard of this problem? I just bought the 4runner "certified used" from a toyota dealer, 117km's on it.

Also:
- brakes feel funny, kinda feels as if the ABS is slightly kicking in.
- rear wiper is broken
- 4Lo won't engage

These 3 i've made an apt to get them fixed but the thump and limp problem i haven't called the dealership on yet.

 

[TeryT]

My driveshaft replacement still hasn't clunked

If you look back to some of the first few pages of this thread, you will see that the dealer replaced my driveshaft with a different one (Lexus?) under my extended warranty. That was about three years and at least 25k miles ago, and still no clunk.

The only thing I do is periodically is shoot a few pumps of Mobile 1 grease into the various zerks. (Yes, I know it calls for specific Toyota spec grease, blah blah blah.)

Every time this thread starts back up, I'm reminded & thankful my clunk hasn't returned. :dancin::girl::drummer:

 

[BIGBLACKV8]

Hey,

I read the first 18-20 pages. At this point i'm not that concerned with the "thump", I'm very concerned about why/how my engine was only working at about 20% of its power, even when I would put the petal to the floor, it barely went anywhere, and the rpm's just crawled up so slowly.