Steering column "clunk" noise?

After replacing my body mount bushings, I've noticed the steering shaft "clunks" when doing over pot holes, bumps, rocks, etc.
I've replaced 45220-04020 (Shaft Assembly Steering) and 45025-04050 (2012-2020 Toyota Tacoma - Hole Cover and bushing), but the noise persists.

^ the above parts were pretty rough, so I don't feel like I wasted my money, but I'd rather find the problem than keep throwing parts at it.

... that said, it seems like the next "higher" part in the steering linkage is some kind of shaft that's freely sliding back and forth in the steering column? I started researching and it seems like a common issue for 1st gen trucks, but not many threads about it on 2nd gens.

Here's a video describing their fix: https://www.youtube.com/watch?app=desktop&v=y_AsS2Km9rE

Like I said, searching only found issues on older trucks - has anyone seen this for our model?




edit: after watching that video, I like this guy's channel - here's one of the other parts I already replaced.
https://www.youtube.com/watch?v=3Dr7df3dRNQ

 

Maybe this part (45250-04221)? https://parts.tomwoodtoyota.com/oem-parts/toyota-main-shaft-4521035260

Lot of money though.

 

Have you checked your upper or lower ball joint? They can definitely be felt through the steering or heard.

Did your original rag doll joint have any slack? I am lazy and shoved a crap ton of zipties to decrease the slope haha

 

Ball joints are fine; they're frequently checked.

Rag joint wasn't bad; I've kept it as a spare or I might try to weld it.

 

Fig'd it have been the intermediate shaft. Ive pretty much replaced all suspension/steering parts EXCEPT the intermediate shaft and i still have the clunk. Annoying as hell. Makes me think somethings busted when off pavement roads

 

Radiator support bushings were changed with body bushings as well? Those radiator bushings will clunk like crazy when they're worn.

 

Yes, they were replaced too.

I can feel the "clunk" in the steering and am pretty certain it is in the steering linkage somewhere.

 

Have you taken off the steering column cover from the inside and inspect the rubber joint at the upper shaft?

 

Yes, and it was replaced with OEM new. "45220-04020 (Shaft Assembly Steering)"

 

I would also check to make sure the 2 12mm bolts that secure the steering column to the dashboard support bar. Mine came loose over time. They sandwich the steering column in between two white plastic spacers/clips.

 

Yep, just checked them, those are fine.

 

get under the truck and have someone turn the steering to full lock one way, then the other way. Watch the rack (may need to remove skid plate) for movement when the steering stops make contact and increased pressure is applied. Our rack is currently shifting back and forth when the stops make contact, making a clunk. Going to try increasing rack bolt torque first.

 

It is rare but not uncommon for those rack bushings to be shot as well

 

I've noticed this: There's a small washer on the steering column shaft that spins freely, if I don't preload it that it's pushing against the housing - I get a clunk. So if you slip the shaft out by a millimeter(sorry no freedom units) out of the lower intermediate shaft and retighten, I found that it fixes the issue.

 

This serrated looking one?!
45263-35020


When I replaced the intermediate shaft, that ring was dangling and wouldn't re-attach to anything.
I'll order a new one, replace it, and update.

 

My column rattled as well and that retaining ring thingy was loose and dangling too. The bottom of the shaft seemed to have wiggle room within the ID of the bearing, so it would rattle against it over bumps and you could move the wheel with your hands a bit. I couldn't find a legit repair besides replacing the whole column assembly so I just 3D printed a spacer "sleeve" of two semi circles and slipped them in the gap between the steering shaft OD and bearing ID.

Hopefully some of that made any sense lol, then I just slid the weird looking ring up against it and threw a hose clamp on to hold it from coming down.

 

I think I understand what you made, but not the stack up order. Any chance you took a photo? Can you share the STL? And did that fix it for you?

 

Yah exactly, what I did was I loosened the uni joint clamp on the rag joint side and just pushed the shaft up towards the steering wheel a tiny bit so it wouldn't free spin anymore(the serated washer), seemed to have solved the issue for me.

 

Yes it did work for me but it sounds like replacing that serrated washer is the proper fix and probably the smarter option for something critical like a steering column. I could send the STL but not sure if I want others doing my kinda "sketchy" repair haha, this is a snip of it to get an idea. The chamfer helps it slide into the gap, with these two halves going around the OD of the shaft and taking up the space to the ID of the bearing to remove the slop. The flange just stops it so that it couldn't slide all the way through. I don't think I ended up using the 3rd little skinny part.

 

Ahh! I get what you mean. I found and ordered a replacement ring, so hopefully they actually have it in stock and it works/fixes the issue. If not... I'll be printing a sleeve too.