NHTSA Complaint #10818805 — 2008 TOYOTA RAV4

VEHICLE DEVELOPED A CLUNK NOISE THAT COULD BE HEARD AND FELT THROUGHOUT THE VEHICLE, ESPECIALLY IN THE STEERING SYSTEM AND ESPECIALLY DURING SLOW SPEED OPERATION. THE PROBLEM BEGAN IN 8/2015 AT ~45,000 MILES. VEHICLE ALSO DEVELOPED A LOOSE FEEL IN THE STEERING AND WOULD PULL TO THE RIGHT UNDER HARD ACCELERATION. BY 1/2016, THE PROBLEM GOT NOTICEABLY WORSE. I THEN TOOK THE VEHICLE TO A LOCAL AUTO REPAIR SHOP FOR DIAGNOSIS/REPAIR. AFTER AN HOUR OR SO OF CHECKING THE ENTIRE SUSPENSION AND STEERING SYSTEM, THE PROBLEM WAS DIAGNOSED AS A BAD "STEERING INTERMEDIATE SHAFT". THE LOCAL SHOP OWNER STATED HE HAD REPLACED SEVERAL OF THESE SAME STEERING SHAFTS ON OTHER RAV4S AROUND THE SAME VINTAGE (2006-2010). I CONTACTED MY LOCAL TOYOTA DEALERSHIP AND THE SERVICE AGENT ALSO STATED THEY HAD "SEVERAL" INCIDENTS WITH THIS VINTAGE OF RAV4S AND STEERING SHAFT PROBLEMS BUT THERE WAS NO RECALL AND SINCE THE VEHICLE WAS OUT OF THE WARRANTY PERIOD, TOYOTA WOULD NOT COVER THE REPAIRS. I THEN LOOKED ONLINE TO SEE IF ANY OTHER OWNERS HAD THE SAME PROBLEM AND WAS SHOCKED TO SEE HOW MANY OTHERS HAVE HAD THE SAME ISSUE WITH RAV4S OF THE SAME VINTAGE AND HAD SIMILAR RESULTS WITH LOCAL TOYOTA DEALERS. I BELIEVE THIS IS A SERIOUS SAFETY CONCERN AS EVENTUALLY THE STEERING SHAFT AND/OR SHAFT U-JOINT KNUCKLES COULD FAIL DUE TO THIS POOR DESIGN AND CAUSE LOSS OF CONTROL (STEERING) OF THE VEHICLE. TOYOTA DOES NOT SEEM TO BE TAKING THIS SERIOUSLY, HOPEFULLY THE NHTSA WILL.