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Some 2009 – 2010 Corolla and Matrix vehicles may exhibit a clunk, pop, or knocking noise when turning the steering wheel to the left or right. A new intermediate shaft has been developed to address this condition. Use the following repair procedure to remove and replace the steering intermediate shaft. Repair Procedure 1. Install a steering wheel lock to ensure the wheels are straight and the steering wheel is centered before removing the steering intermediate shaft. Make sure the steering wheel and front wheels remain stationary. Once the intermediate shaft is removed, do NOT allow the steering wheel to spin freely. 2. Remove the column hole silencer sheet. 3. Place a matchmark on the No. 2 steering intermediate shaft that will later be copied onto the new part, and remove the bolt. 4. Place a matchmark on the upper portion of the No. 2 steering intermediate shaft. 5. Remove the bolt and the No. 2 steering intermediate shaft assembly from the steering column assembly. 6. Place the matchmarks on the NEW steering intermediate shaft sub-assembly. A. Place the NEW steering intermediate shaft next to the original steering intermediate shaft assembly (removed in the previous step). B. Transfer the matchmarks on the original steering intermediate shaft to the same locations on the NEW steering intermediate shaft. Figure 5. 1 Original Steering Intermediate Shaft 7. Install the NEW No. 2 intermediate shaft and line up the matchmarks and tighten the bolt. Torque: 35 N*m (360 kgf*cm, 26 ft*lbf) 8. Install the No. 2 intermediate shaft onto the No. 1 intermediate shaft and line up the matchmarks, and tighten the bolt. Torque: 35 N*m (360 kgf*cm, 26 ft*lbf) 9. Reinstall the column hole silencer sheet. 10. Road test the vehicle to verify the repair and con?rm that the steering wheel is centered.

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NOTE: Removal and installation steps are the same for both camshaft and auxiliary shaft sprockets. Removal 1. Remove outer timing belt cover as outlined in this section. 2. Remove timing belt as outlined in this section. 3. Install Cam and Auxiliary Shaft Sprocket Tool T74P-6256-B on sprocket. Use tool to hold sprocket and remove bolt and washer. 4. Install threaded puller insert in Cam and Auxiliary Sprocket Tool T74P-6256-B and remove sprocket. 5. Remove tool from sprocket. Installation 1. Position key and sprocket on shaft. 2. Install Cam and Auxiliary Shaft Sprocket Tool T74P-6256-B, without threaded puller insert, on sprocket. 3. Install sprocket bolt and washer and tighten to 70-95 Nm (52-70 ft-lb). 4. Remove tool. 5. Install timing belt as outlined in this section. 6. Install outer timing belt cover as outlined in this section.

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1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100-00. 2. Remove the rear wheel and tire assembly. For additional information, refer to Section 204-00. 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. 5. Fill the axle with the specified quantity of the specified lubricant. For additional information, refer to the Specifications in this section. Item 2: Rear Disc Brake Caliper Removal Note 1. CAUTION: Do not allow the caliper to hang from the brake hose. Provide a suitable support. Position the rear disc brake caliper aside. For additional information, refer to Section 206-00. Item 7: Differential Pinion Shaft Removal Note 1. Move the differential pinion shaft out far enough to remove the U-washers. Replace the shaft and install the lock bolt finger tight when U-washers are removed. Item 8: U-washer Removal Note 1. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Remove the U-washers. 1. Push the axle shafts inboard. 2. Remove the U-washers. Item 10 and 11: Wheel Bearing Oil Seal and Axle Shaft Bearing Removal Note 1. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. For the 8.8 inch rear axle, use the special tools to remove the rear wheel bearing and wheel bearing oil seal. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. For the 9.75 inch and the 10.25 inch rear axles, use the special tools to remove the rear wheel bearing and wheel bearing oil seal. Item 11: Axle Shaft Bearing Installation Note 1. For the 8.8 inch and the 9.75 inch rear axles, use the special tools to install the rear axle wheel bearing. 2. For the 10.25 inch rear axle, use the special tools shown to install the rear axle wheel bearing. Item 10: Wheel Bearing Oil Seal Installation Note 1. Use the special tools shown to install the rear wheel bearing oil seal. Item 8: U-washer Installation Note 1. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers. 1. Position the two U-washers on the button end of the axle shafts. 2. Pull the axle shafts outward.

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Removal NOTE: If, for any reason, the rear hub (1109) is removed from the spindle, the old hub seal must be removed and a new hub seal installed. 1. Set the parking brake and loosen the eight axle shaft retaining bolts. 2. Raise the vehicle to the desired working height, keeping the axle parallel with the floor. 3. Release parking brake and back off the rear brake adjustment, if necessary. 4. Remove the wheel (1007). 5. Remove brake drum (1126). Push-on (sheet metal) drum retainer nuts may be discarded. Push-on retainer nuts are used for shipping purposes only and have no vehicle function. If retainers are not flush against the drum, the retainers can prevent the wheel from being flat against the drum, which could contribute to vibration. 6. Place a drain pan under the axle shaft (4234) and rear hub. Remove the eight 7/16-inch axle shaft bolts and remove the axle shaft. Axle Shaft Removal 7. CAUTION: The right hub nuts are right-hand thread; the left hub nuts are left-hand thread. Each hub nut is stamped RH for the right hub nut or LH for the left hub nut. Install Locknut Wrench T85T-4252-AH so that the drive tangs of the tool engage the four slots in the hub nut. 8. CAUTION: A new hub nut must be installed if used hub nut comes apart during removal or installation. CAUTION: Under no circumstances are power impact tools to be used when performing these operations. NOTE: The hub nut will ratchet during this operation. Remove hub nut (counterclockwise for right-hand thread; clockwise for left-hand thread). 9. Install Step Plate Adapter D80L-630-7 (Part of Step Plate Adapter Set D80L-630-A) or equivalent. 10. Install 2-Jaw Puller D80L-1002-L or equivalent and loosen rear hub to the point of removal. 11. CAUTION: Do not drop outer hub bearing when removing. Remove rear hub assembly.

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1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist enough to allow the rear axle to drop into the rebound position for working clearance. For additional information, refer to Section 100-02. 2. Remove the rear wheel and tire assembly. For additional information, refer to Section 204-04. 3. Remove the brake drum. For additional information, refer to Section 206-02. 4. Remove the differential housing cover (4033) and drain the lubricant. Clean the gasket material from the differential housing cover and the differential housing (4010). 5. CAUTION: The differential assembly is equipped with either a Loctite® coated differential pinion shaft lock screw or a differential pinion shaft lock screw with torque prevailing threads. The Loctite® treated differential pinion shaft lock screw has a 5/32-inch hexagram socket head. Never, under any circumstance, reuse a Loctite® coated screw after removing it. Always discard the screw and install a new one. The torque prevailing differential pinion shaft lock screw has a 12-point drive head. This type of screw is reusable for no more than four installations. When in doubt about the number of installations of a torque prevailing differential pinion shaft lock screw, discard it and install a new screw. Remove the lock screw. 6. Remove the differential pinion shaft (4211). The pinion shaft is a slip-fit design and is removable by hand. 7. Push the flanged end of the axle shaft (4234) toward the center of the axle and remove the U-washer (4N237).