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4WD Rear Propeller Shaft (Driveshaft) Clunk/Thunk Noise

178K views 443 replies 197 participants last post by  FJtest  
#1 ·
Introduction
Some 4WD equipped 2007 – 2012 model year FJ Cruiser vehicles may exhibit a clunk/thunk
noise from the rear of the vehicle or a “bump-from-behind” sensation just before a stop or when
accelerating from a stop. Improvements have been implemented on the rear propeller shaft
(driveshaft) to reduce this condition. Utilize the following repair procedure to address this condition.

Not sure is this the right section for this, please move if needed.
 

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#2 ·
Thanks for posting this. I'm surprised Toyota cam out with a TSB on this since they all seem to do it. I'm way out of warranty so I guess I'll just keep greasing mine every 3-5,000 miles.

DEWFPO
 
#4 ·
And I always thought that was my links making that noise...

Thanks for the post
 
#5 ·
My 2008 makes the "clunk" noise if I don't lubricate the splines for more than 10k miles. But lubricating the driveshaft every 10k miles with high quality synthetic grease seems to eliminate the problem. It seems like an expensive fix for something that can be resolved with a simple maintenance procedure.
 
#6 ·
This has made my day...and its only 6:00am. I had this in my Tacoma and it drove me INSANE. Got the FJ only to find out that it was happening on it too. Every Toyota dealer told me its "normal". I'm taking this in to my dealer ASAP and rubbing his nose in it.

Thanks for posting!
 
#8 ·
Absolute worst customer service expierence with Toyota Canada Head office this morning, and Maple Toyota service manager. I strongly suggest not having any work done their for any Canadians, they made it very clear that their only concern is making money - stated this to me twice.

Also Head Office said since this is a USA bulletin it means nothing to them in Canada.

If any once has any expierence in dealing with Toyota Head Office or alternate contact means rather then feedback_Toyota@toyta - I emailed them this service bulletin they don;t care becuase it is from the USA, please share them.

Thanks
TGIF
 
#33 ·
Toyota Canada still falls under Toyota North Americas(Mexico/US/Canada) which falls under big daddy Japan.. Alotta times they dont always all work well together but... Im not sure why a Canada dealership is not honoring it the FJ is made in Asia... its simple warrenty work they get paid by Toyota to fix it, its not costing them anything.(well warrenty work pays less then normal work but still...)

If your able to find a Contact or Support at North Americas they are above your dealership.. however remember that dealerships are privately owned i.e. like franshise generally so.. they may still refuse work etc.. However if you keep at it and find someone at north americas who can help alotta times a phonecall from then to your dealership can get your fixed up... might take time and effort but may fix your situation... I however would recomend if possible going to a different Toyota dealership and when you get there be polite and inform them that you just had a bad experience with another toyota dealship(they still compete against each other for your buisnes) and that your just triying to get your vehicle fixed under warrenty. *they may be more friendly and open to helping you in hopes of getting your future buisness.

A quick search found this link but im sure if you google deep enough youll find more: Toyota Help <-- as good as anywhere to start...
 
#9 ·
This is one of those things that has been happening constantly with my almost new 2012 FJ, and I probably would have eventually noticed it, but after reading about this (in another thread) I notice it all the time. I'm already scheduled for some service in May, I'll call and ask about having them check this out.
 
#13 ·
My 2011 has been doing this since I got it. It felt like someone hit me the other day when it happened! I'm glad you posted this. I'm heading to the service department next week with TSB in hand. I'll post back what they say.
 
#14 ·
I called the dealership on Friday and told them about the TSB. They had already replicated and documented the clunk when I brought it in for my 10k mile service a few weeks ago. Once they had the TSB, they ordered (supposedly) the new part for me and said they'd give me a call when it came in.

I nearly laughed out loud when the service rep that told me it was "normal" just a few weeks ago told me that he's glad they released this TSB because "it's a problem that Toyota has been having for a while." I'm starting to learn that if the car is still starting/rolling and there's no TSB for the issue then its just "normal".

I'll update when I go to get the new driveshaft assembly installed.
 
#16 ·
Mine happens very rarely. Which means the dealer will tell me they can't duplicate and do the repair Im sure..
 
#17 ·
Drive with them. Turn the AC on. Stop quickly at a stop. After 10 or 20 seconds Very slowly ease of the brake. For my truck this is the perfect combo for a clunk forward.

sent from my Droid....using the paid auto guide app that rarely works properly
 
#20 ·
Just talked with my service rep at Performance Toyota in Memphis and they are ordering the part and he is going to call me when its in to do the warranty work. Hopefully this week, I'll get it fixed and test it out.
 
#21 ·
90K miles, with documented complaint on previous service records, I think the odds are slim to none.
 
#23 ·
My service rep called today and said the new drive shaft assembly came in. Set up an appointment to get it installed on Friday. Will follow up with results.
 
#24 ·
The updated rear propeller drive shaft assembly. They are going to replace mine once this one comes in.
 
#25 ·
The part is in and I have an appointment on Friday to get it replaced.
 
#26 ·
Make room for me! Well I'd always blamed this on digger, and even went as far to replace his hardware with some having a longer grip length. However even after doing this the noise is still present. So, appt has been made for 3-13, well see what BS the dealership tells me this time! Thanks for the info on this issue.
 
#27 ·
Just got back from the dealer. The entire driveshaft assembly was replaced. No clunks on the way home but that doesn't mean its fixed! My FJ didn't start clunking until I had a couple thousand miles on it...probably by the time some of the grease had worked its way out of the spline and slip yokes.

Anyways I drove it home and mashed the brakes hard a few times coming to a full stop and felt no clunk so that's better than what I had! I'll check in again once I get some more miles on it. If I'm feeling adventurous I may get under there and take some pictures to see if anybody can spot what they changed.
 
#28 ·
Just got back home from the dealership getting the driveshaft assembly replaced. I couldn't make the clunk happen on the way home so maybe its fixed :clap: Of course it could start back after its driven a while but I'll post back later and give an update.
 
#29 ·
So far, so good. Drove a good bit all day saturday and no clunks. Here's some pics I took with my cell phone. Is the grease suppose to sling out like that??

Front of driveshaft
Image


Rear of driveshaft
Image


Sticker on driveshaft
Image


Closeup of rear
Image
 
#30 ·
Holy crap, they over greased the hell out of that!