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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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1. Disconnect battery ground cable (14301) . Refer to Section 14-01. 2. Remove steering wheel (3600) as described. 3. Remove steering column from vehicle as described. 4. Remove steering column lower yoke (3N725) , steering column upper bearing spring (3520) , suspension height sensor control ring (3C131) and steering column bearing tolerance ring (3L539) . Lower Steering Column Assembly 5. Remove turn indicator cancel cam (13318) by pushing up with flat-bladed screwdriver. Note direction of flush surface. 6. Remove ignition switch (11572) . 7. Remove bearing retainer (3C610) and steering column upper bearing spring . 8. Remove steel steering column bearing tolerance ring and steering column bearing sleeve (3518) . 9. Remove plastic bearing retainer from ignition switch lock cylinder bore. 10. Remove metal steering column lock housing bearing (3E700) from ignition switch lock cylinder bore. 11. Note position of steering column lock gear (3E717) to actuator lock. Remove steering column lock gear . 12. Remove two pivot bolts. Use caution as steering column position spring (3D655) will release when bolts are removed. Remove steering column lock cylinder housing (3511) . 13. Remove steering column shaft assembly from steering column. 14. Remove steering column lock lever actuator (3E715) and steering actuator housing (3F723) . 15. Remove lower steering column bearing (3517) and steering column lower bearing retainer (3D681) . 16. Remove tilt position lever pivot pin using a drift. Remove RH steering column locking lever (3B661) (RH and LH), steering column lock left hand lever (3D653) and steering column locking lever springs (3B664) . Assembly 1. Install steering column shaft assembly into steering actuator housing . 2. Install lower steering column bearing and steering column mounting bracket (3E660) . Tighten screws to 7-11 Nm (62-97 lb-in). 3. Install suspension height sensor control ring , steering column bearing tolerance ring , steering column upper bearing spring and steering column lower yoke to steering column shaft assembly. Tighten pinch bolt to 25-35 Nm (19-25 lb-ft). Item 1 2 3 4 5 A 4. Position actuator cam in steering column lock cylinder housing and install cam pivot pin with small hammer. Tap pin in until flush with steering column lock cylinder housing . 5. Install one steering column locking lever spring and RH steering column locking lever into steering actuator housing using a drift to hold in place. 6. Install the LH steering column locking lever spring and steering column lock left hand lever with steering column lock actuator lever pin (3F530) . Tap steering column lock actuator lever pin into place while driving out drift. Part Number N803942 3L539 3C131 3520 3N725 — Description Pinch Bolt Steering Column Bearing Tolerance Ring Suspension Height Sensor Control Ring Steering Column Upper Bearing Spring Steering Column Lower Yoke Tighten to 25-35 Nm (19-25 Lb-Ft)

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CAUTION: Do not remove the steering column, steering wheel and air bag module as an assembly from the vehicle unless the column is locked to prevent rotation, or lower end of steering shaft is wired in such a way to prevent the steering wheel from being rotated, as this will damage the air bag sliding contact. 1. Disconnect battery ground cable (14301). Refer to Section 14-01. 2. Remove steering wheel (3600) as described. 3. Remove steering column from vehicle as described. 4. Remove steering column lower yoke (3N725), steering column upper bearing spring (3520), suspension height sensor control ring (3C131) and steering column bearing tolerance ring (3L539). Lower Steering Column Assembly 5. Remove turn indicator cancel cam (13318) by pushing up with flat-bladed screwdriver. Note direction of flush surface. 6. Remove ignition switch (11572) assembly. 7. Remove bearing retainer (3C610) and steering column upper bearing spring. 8. Remove steel steering column bearing tolerance ring and steering column bearing sleeve (3518). 9. Remove plastic bearing retainer from ignition switch lock cylinder bore. 10. Remove metal steering column lock housing bearing (3E700) from ignition switch lock cylinder bore. 11. Note position of steering column lock gear (3E717) to actuator lock. Remove steering column lock gear. 12. Remove two pivot bolts. Use caution becausesteering column position spring (3D655) will release when bolts are removed. Remove steering column lock cylinder housing (3511). 13. Remove steering column shaft assembly from steering column. 14. Remove steering column lock lever actuator (3E715) and steering actuator housing (3F723). 15. Remove lower steering column bearing (3517) and steering column lower bearing retainer (3D681).

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Removal NOTE: Mark the pinion yoke and driveshaft to make sure the yoke and driveshaft are correctly aligned during assembly. 1. Remove the nuts and U-bolts connecting the driveshaft to the yoke. Disconnect the driveshaft from the yoke. Wire the driveshaft out of the way, so it will not interfere in the carrier removal process. 2. Remove both spindles and the Left and Right Shaft and U-joint assemblies as described in the Removal and Installation portion of this Section under Spindle and Left and Right Shaft and U-joint Assemblies. 3. Support the carrier with a suitable jack and remove the bolts retaining the carrier to the support arm. Separate the carrier from the support arm and drain the lubricant from the carrier. Remove the carrier from the vehicle. 4. Place the carrier in a Holding Fixture, T57L-500-B with Adapters T90T-4000-A. 5. Rotate the slip yoke and shaft assembly so the open side of the snap ring is exposed. Remove the snap ring from the shaft. 6. Remove the slip yoke and shaft assembly from the carrier. 7. Remove the oil seal and caged needle bearings at the same time, using Slide Hammer, T50T-100-A and Collet, D80L-100-A or equivalents. Discard the seal and needle bearing.

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Removal 1. Raise and support vehicle. Remove wheel assembly. Remove caliper from rotor. Remove locking hub. See AUTOMATIC LOCKING HUBS or MANUAL LOCKING HUBS under REMOVAL & INSTALLATION. 2. Remove wheel bearings, lock nuts, hub and rotor. Remove spindle-to-steering knuckle nuts. Tap spindle with plastic hammer to free spindle from steering knuckle. See Fig. 9 . Remove spindle, spindle seat (if equipped) and splash shield. 3. On right side applications, remove and discard keystone clamp from shaft assembly and stub shaft. Slide rubber boot onto stub shaft. Remove shaft assembly from right axle. See Fig. 9 . 4. Remove left shaft assembly (if required). On all applications, wrap spindle in protective cloth and place second step of spindle in soft-jawed vise. 5. On Explorer and Ranger, remove oil seal using slide hammer and Seal Remover (TOOL-1175-AC). Remove needle bearing from spindle. Press seal from shaft assembly. See Fig. 9 . 6. On Bronco and F150, remove needle bearing and oil seal using slide hammer and Cup Puller (T77F- 1102-A). Press seal from shaft assembly. Installation 1. Clean all dirt and grease from spindle bearing bore. Ensure bearing bore is free of nicks and burrs. On Explorer and Ranger, install seal on shaft assembly using press and Seal Installer (T83T-3132-A). 2. On Bronco and F150, install seal on shaft assembly, with seal lip toward spindle. On right side applications, install rubber boot and NEW keystone clamps on stub shaft. Install right shaft assembly into stub shaft, with stub shaft missing spline aligned with shaft assembly. 3. Ensure splines are fully engaged. Install rubber boot over assembly and tighten keystone clamps. On left axle applications, install shaft assembly through steering knuckle, and engage in splines. 4. Install needle bearing in spindle, with manufacturer identification mark facing away from spindle bore. For bearing installation, use Handle (T80T-4000-W), and Bearing/Seal Installer (T83T-3123-A for Explorer and Ranger; T80T-4000-S for Bronco and F150). CAUTION: Install spindle needle bearing with manufacturer’s identification mark away from spindle bore.