griffill,

I owned a 2004 Sienna XLE (vin 266) until just a few days ago. With such any early production unit (vin 266 / Jan 2003) meant that my Sienna ran into just about every problem known to the current generation Sienna, including the steering intermediate shaft problem you're experiencing.

There is a TSB on this very issue (issued 2/6/2004) ST003-04. The TSB outlines the replacment of the steering intermediate shaft to eliminate a squeak, pop or click noise is heard or felt in the steering while making turns. The TSB states that this issue is only covered under for 36 months or 36,000 miles, whichever occurs first.

The best I can say to you is I hope you complained about the noise/problem before the 3 year/36k mile point and have it documented on a service repair order (with no problem found). You might be able to get them to cover the issue (as they should have then) under this TSB.

When I have this steering intermediate shaft replace, it may a WORLD of difference in the steering of my Sienna.

I hope that helps.

 

We are experiencing the same problem with our 2004 Sienna. We took our van in when it was under warranty, around 22k miles, for a clicking or popping in the front end while primarly turning left. This was the fix that was listed: the bolt at right lower control arm to subframe cross threaded, repaired bolt and mount and tightened.

Now at 37k miles, the popping or clicking while turning left is back worse than ever. We took the van in to let them look at it and now they say we need to replace the intermediate steering shaft. We left the dealer and called them back to say that we had the van in, while under warranty, for the same type of problem to see if they would cover it under warranty and they looked at the records and said the problems are different. They went on and said that they would not cover the intermediate shaft under warranty.

Should the second problemn be covered under the original warranty and initial visit?

 

I had two repair visits for "loose bolts" in the front suspension (about 8000 miles apart) on my 2004 Sienna in addition to the intermediate shaft issue.

I can "kind of" see the point being made by your service department in that if the noises did go away after the first repair (bolt issue) that they are two seperate problems.

If the service department (manager) is customer friendly, they should try and work with Toyota, since a TSB does exist for the intermediate shaft problem, to see if they could get it covered under warranty (good will) via the TSB. If you're around 37K miles the amount over 36K is small unless you've owned the Sienna several months over 3 years.

You can always approach another Toyota service department with the issue to see if they'll be more willing to work with you on the issue.

 

shiftz33,

Thanks for your reply and advice...

Yes, you are correct we are just over 36k miles.

 

I know this is an old post but... I am stationed in the UK and just started having this problem on my 05 sienna with 55K miles. How much did this cost? How big and heavy is the part. Is it shippable by USPS and if so is it an easy repair job? There are mechanics here that can do the work or I might be able to do it myslelf if it is not too difficult. As you can imagine, I can't get the part here though. Please reply with any help.