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Failure analysis: Intermittent horn #4447522
07/02/17 03:18 PM
07/02/17 03:18 PM
Joined: Apr 2016
Posts: 814
Specific Ocean
Kibitoshin Offline OP
Kibitoshin  Offline OP

Joined: Apr 2016
Posts: 814
Specific Ocean
01 Tundra didn't pass it's yearly safety check due to inop horn which now means solving an electrical issue since this is now a critical fix. I've checked the most basic stuff until I did some googling that similar Tundra owners had with the column shaft tilt assy bearings. The horn button completes the ground circuit from the chassis, through the bearings, horn button, then to the horn relay. Wiggling the steering wheel while holding the horn completes the ground as the rusty bearings try to ground to chassis so that confirms the issue.




I opted to replace the whole assembly instead of cleaning the old grease and repacking it with new grease. The failure seems to be a lack of grease in the bearings from the factory and bearings open to the elements. The new assembly also lacked grease. In this case I encased the new bearings with white lithium grease to prevent open exposure to rusting.
I also replaced the column shifter assembly with the updated version since they are prone to breaking.


Shin Gekiretsu Shin'ou'hou
01 Toyota Tundra 2WD V8 4.7L
02 Chevy Silverado C1500 V8 5.3L
Re: Failure analysis: Intermittent horn [Re: Kibitoshin] #4447530
07/02/17 03:29 PM
07/02/17 03:29 PM
Joined: Mar 2004
Posts: 21,820
Upstate NY
Donald Offline
Donald  Offline

Joined: Mar 2004
Posts: 21,820
Upstate NY
Portable freon boat horn in a can?


2015 Subaru Forester 2.5 engine/CVT
2015 Ford F250 w/Powerstroke
2016 Subaru Crosstrek CVT (wife's)
Re: Failure analysis: Intermittent horn [Re: Kibitoshin] #4447560
07/02/17 04:07 PM
07/02/17 04:07 PM
Joined: Sep 2007
Posts: 1,123
TX, USA
JMJNet Offline
JMJNet  Offline

Joined: Sep 2007
Posts: 1,123
TX, USA
For the horn, not sure if you checked the fuse?
I had experience with a good old fuse that cause intermittent issue with the horn.
I replaced it and it was good to go, not sure why.


  • 2017 Toyota Sienna
  • 1995 GMC Suburban 6.5L Turbo Diesel


Re: Failure analysis: Intermittent horn [Re: Donald] #4447563
07/02/17 04:10 PM
07/02/17 04:10 PM
Joined: Apr 2016
Posts: 814
Specific Ocean
Kibitoshin Offline OP
Kibitoshin  Offline OP

Joined: Apr 2016
Posts: 814
Specific Ocean
Originally Posted By: Donald
Portable freon boat horn in a can?


If safety checks weren't mandatory lol. I don't use the horn a lot so I didn't find out until the mechanic told me the horn wasn't working.

Picture of the new assembly. Insufficient amount of grease in the bearings possibly leading to repeat failure. Forgot to add to original post.



Shin Gekiretsu Shin'ou'hou
01 Toyota Tundra 2WD V8 4.7L
02 Chevy Silverado C1500 V8 5.3L
Re: Failure analysis: Intermittent horn [Re: JMJNet] #4447571
07/02/17 04:16 PM
07/02/17 04:16 PM
Joined: Apr 2016
Posts: 814
Specific Ocean
Kibitoshin Offline OP
Kibitoshin  Offline OP

Joined: Apr 2016
Posts: 814
Specific Ocean
Originally Posted By: JMJNet
For the horn, not sure if you checked the fuse?
I had experience with a good old fuse that cause intermittent issue with the horn.
I replaced it and it was good to go, not sure why.


Yep checked the fuse and related connections with a DMM. I almost chalked it up to a broken wire in the engine bay but I remember coming across a similar issue with another vehicle and I checked the horn pad/button. Further googling came out to be poor ground connections through the bearings.


Shin Gekiretsu Shin'ou'hou
01 Toyota Tundra 2WD V8 4.7L
02 Chevy Silverado C1500 V8 5.3L
Re: Failure analysis: Intermittent horn [Re: Kibitoshin] #4447585
07/02/17 04:27 PM
07/02/17 04:27 PM
Joined: Sep 2004
Posts: 8,009
Marshfield , MA
andyd Offline
andyd  Offline

Joined: Sep 2004
Posts: 8,009
Marshfield , MA
May I be so rude as to inquire the price of the assembly? I would have tried to drive out the bearing, clean it, and repack it with wheel bearing grease. If not, I would have cleaned and repacked it in place.This bearing doesn't have very much stress on it.


'16 Camry LE STP synth 0w20 and STP filter. the Fridge

1994 Ranger ,the Rat, 5w30 dino, STP filter

'16 Camry SE, Valvoline HM 0w20 and OEM filter
Thick oil is better grin2
Re: Failure analysis: Intermittent horn [Re: andyd] #4447616
07/02/17 04:55 PM
07/02/17 04:55 PM
Joined: Apr 2016
Posts: 814
Specific Ocean
Kibitoshin Offline OP
Kibitoshin  Offline OP

Joined: Apr 2016
Posts: 814
Specific Ocean
Originally Posted By: andyd
May I be so rude as to inquire the price of the assembly? I would have tried to drive out the bearing, clean it, and repack it with wheel bearing grease. If not, I would have cleaned and repacked it in place.This bearing doesn't have very much stress on it.


I paid $80.01 but price varies with the dealership. Toyodiy.com shows it at $63.62.

Last edited by Kibitoshin; 07/02/17 05:00 PM.

Shin Gekiretsu Shin'ou'hou
01 Toyota Tundra 2WD V8 4.7L
02 Chevy Silverado C1500 V8 5.3L
Re: Failure analysis: Intermittent horn [Re: Kibitoshin] #4447653
07/02/17 05:47 PM
07/02/17 05:47 PM
Joined: Apr 2012
Posts: 6,274
MA
Wolf359 Online content
Wolf359  Online Content

Joined: Apr 2012
Posts: 6,274
MA
Originally Posted By: Kibitoshin

If safety checks weren't mandatory lol. I don't use the horn a lot so I didn't find out until the mechanic told me the horn wasn't working.


I'm not sure I can go anywhere without using the horn at least once. Lots of crazy drivers here that don't pay attention. Sometimes you really have to lean on it too otherwise they would just crash into you when they switch lanes without checking their blind side. I cringe all the time when I see drivers backing up just using their rear view mirror, they'll get a nice view just before they hit someone.

Re: Failure analysis: Intermittent horn [Re: Kibitoshin] #4447743
07/02/17 07:30 PM
07/02/17 07:30 PM
Joined: Jun 2003
Posts: 18,404
Deplorable in apple valley, ca
Chris142 Offline
Chris142  Offline

Joined: Jun 2003
Posts: 18,404
Deplorable in apple valley, ca
I think packing it with grease will cause no contact and no horn.


02 Wrangler carlube 5w30
87 F250 traveler 15w40
07 fjcruiser Chevron 10w30
Z400 castrol T 10w40
Can am maveric edge 5w40
57 case tractor 15w40
Re: Failure analysis: Intermittent horn [Re: Kibitoshin] #4447864
07/02/17 10:07 PM
07/02/17 10:07 PM
Joined: Oct 2014
Posts: 13,284
Canyon County Idaho
CT8 Offline
CT8  Offline

Joined: Oct 2014
Posts: 13,284
Canyon County Idaho
You fixed it right the first time Good job! I quit Micky Mousing things about 40 years ago.


2015 Ford F150 2.7
2018 Ford F350 6.2
Re: Failure analysis: Intermittent horn [Re: Kibitoshin] #4447896
07/02/17 10:43 PM
07/02/17 10:43 PM
Joined: Apr 2005
Posts: 590
Under the hood
Carmudgeon Offline
Carmudgeon  Offline

Joined: Apr 2005
Posts: 590
Under the hood
I had a different failure mode in an old Mazda beater.

Intermittently, the horn would sound on its own in the middle of the night.

"Who's that idiot blowing their horn and disturbing the peace?"

Oops, that idiot was me.

The horn pad/switch was a sandwich of two sheets of copper fingers separated by a layer of foam.

Over time, the foam disintegrates, and you can guess what comes next.

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