Zip tie mod fail... Steering shaft knocking worse

Maybe I have gone too far down the rabbit hole... need some help or advice.

I have a 2011 DCSB 80k miles good shape overall but has the steering wheel knock sound going down dirt roads or bumps etc... I read the thread on zip ties in the rag joint bushing and tried it. The knocking sound was 90% better. That's where I should have stopped.

Reading more threads I saw someone fixed the issue by shortening the steering shaft and loading the rag joint. This was done by releasing the top bolt of the shaft clamp (in engine compartment) and pushing down on the exposed shaft until only a few mm is visible. Here is the post...

https://www.tacomaworld.com/threads/steering-column-final-fix.277292/#post-8935421

I figured this was better than zip ties so I tried it. The issue is the steering shaft and locking collar is pretty rusty. I am not even sure I moved it. To put downward pressure on the shaft I pried down off the upper u-joint (under dash). So not being successful with that, I decided to retreat back to the zip tie method. However I have no more big zip ties, so I used 2 smaller ones on opposite sides. If I had to guess I would say overall its tighter than with one.

Long story short, I drove it and now the knock/noise is worse than ever! It is louder than before. Now what??? I probably f'd my self. I may try going back to the larger zip tie but my suspicion is I caused more damage. I can say the upper U-joint does have visible play. Not sure if it did before.

Maybe time to replace the whole shaft? Let me know your thoughts. Thanks!

 

I tried all the zip tie stuff as well. Finally replaced the shaft with the new part number from the TSB.

TSB attached. Did it in my garage with help from a friend.
Parts required:
Qty. 1 45220-04020 Shaft Assy, Steering Intermediate
Qty. 2

$8 90080-11555 Bolt With Washer For Steering Column And Shaft

90080-11555 Bolt, w/Washer

$181 in parts; worth every penny.
Pretty easy with two people.
Here is the old one:

 

Kind of my thought too. My concern is separating the the lower part of the shaft. It looks pretty rusty and there is no good way to push them apart.

My other fear is I swap out the shaft and still have the issue. Everything has risks...

 

True, no guarantees. Either replace all the way down to the rack or soak that joint in PB Blaster before you start trying to separate it.

 

Just swapped zip ties (because why not?) cut out the two smaller ones and replaced with one larger one. Good news it is better. Bad news is a different sound. Before was a duller knocking sound when going over bumps. That is mostly gone but now on the biggest hits there is more of a metallic noise. I would guess its either the upper u-joint or the lower steering column bearing. There is some slight radial play in the column.

My guess is jamming the zip tie in there sends more NVH up the steering column. Nothing beats a properly engineered rag joint to eliminate noise and vibration but still provide feel.

 

So I bought a new shaft and in the process of swapping it out. What a pain! The old one is marked and loose on both ends but does not slide enough to pull it out.

Does it slide up first or down? What coupler is disconnected first?

Thanks

 

Yeah I read that but it didn’t work. Both couplers would move but not enough to slide the shaft out.

I just unbolted the column and moved it up a bit. No big deal.

Bottom line is it is done and feels 100% better.

 

Bump! I did a write up for a zip tie mod killer! Let me know if it helps anyone!!!

https://www.tacomaworld.com/threads...-fix-zip-tie-mod-killer.702754/#post-24912139