Started hearing a clunking or knuckle popping noise that could also be felt in the steering column at around 75,000 miles. My mechanic thought it may be a brake pad issue so he replaced the front pads. No change. At 80,000 miles I still have the same issue only worse. Found various complaints on this issue with the fixes being either to replace the intermediate steering shaft or to check the axle nuts for proper torque. Mechanic re-torqued the axle nuts but the problem still exists. Starting from stop or at very low speeds, going forward or backward, and making a hard left or right turn causes the noise. Based upon other reports, it is probably the intermediate steering shaft. As an engineer in the safety industry this has me greatly concerned since most of my driving is highway at 65 and above. Concerned that I could have a steering failure while driving. This should be a mandatory recall.

2009 Rav4 with 42500 miles developed popping in steering while making low speed turns, say 15-20 mph. Started when it was under warranty and like a bonehead I didn't look into it at the time thinking it was nothing. I mean, its a Toyota with 36K miles, what would be wrong? $517.00 later to replace the shafts I learned my lesson. Add a stereo that just dies for no reason and requires a rap on th side of it to start working again, and I'm no Toyota fan anymore.

I reported my complaint to nhtsa.gov because I believe that this popping will eventually bind and cause loss of life. It would be wise to do the same. It should be recalled by Toyota but Toyota firmly denies any claim that is out of warranty.