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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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Removal 1. If equipped with power seats, move the seat fully rearward. 2. If equipped with adjustable pedal system, move the pedal to the full forward position. 3. If equipped with a manual transmission, place the transmission in second gear. 4. Remove the passenger air bag module. For additional information, refer to Section 501-20B. 5. Close the glove compartment. 6. Position the battery junction box (BJB) aside. Release the mounting tabs. 7. Remove the bulkhead electrical connectors from inside the engine compartment. 1. Loosen the bolts. 2. Disconnect the bulkhead electrical connectors. 8. Remove the bulkhead electrical connector insulator. 9. Unclip the bulkhead electrical connectors from the dash panel. 10. Remove the instrument panel steering column cover. For additional information, refer to Instrument Panel — Steering Column Cover in this section. 11. If equipped, remove the valance panel. Remove the two pin-type retainers and release the expander clip. 12. Disconnect the restraint control module (RCM) electrical connector. 1. Release the locking tab. 2. Disconnect the RCM electrical connector. Release the wiring harness locators. 13. Disconnect the electronic blend door actuator electrical connector. Release the wiring harness locators. 14. Disconnect the climate control head vacuum harness connector. 15. Remove the LH and RH front door scuff plates. 16. Position the LH and RH door weatherstrip seals aside. 17. Remove the LH and RH A-pillar lower trim panels. 18. If equipped, remove the alternative fuel control module (AFCM). 1. Disconnect the electrical connector. 2. NOTE: The AFCM is attached with Velcro®. Remove the AFCM from the vehicle by pulling gently down and to the right. 19. Remove the LH and RH A-pillar passenger assist handles. 1. Remove the four screw covers and four screws. 2. Remove the LH and RH A-pillar passenger assist handles. 20. Remove the LH and RH windshield side garnish mouldings. 21. Disconnect the brake pedal position (BPP) switch electrical connector. Release the wiring harness locators.

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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Disconnect the negative battery cable. Remove the floor console. Remove the sun sensor and the automatic temperature controls assembly. Remove the tweeter speakers and the stereo cassette AM/FM radio. Refer to Section 9F, Audio Systems. Remove the screws and the instrument panel storage compartment. Remove the instrument cluster dimmer switch assembly. Remove the instrument cluster. Remove the chime module. Remove the kick panels. Remove the glove box. Remove the screws and the glove box housing. Disconnect the glove box housing electrical connectors. Remove the knee bolster. 14. Remove the nuts and the bolts securing the steering column. 15. Disconnect the steering column electrical connectors. 16. Lower the steering column. 17. Remove the screw behind the stereo cassette AM/FM radio. 18. Remove the screw securing the instrument panel to the heater air distributor case. 19. Remove the bolts and the glove box brace. 20. Remove the instrument panel screw behind the glove box brace. 21. Remove the instrument panel bolts below the windshield. 22. Remove the bolts securing the bottom of the instrument panel to the floor. 23. Remove the bolts securing the sides of the instrument panel to the body.

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Instrument Panel Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Depower the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in Section 501-20B. 2. Remove the LH front wheel and tire assembly. For additional information, refer to Section 204-04. 3. Position the LH fender splash shield away from the dash panel. 1. Remove the pin-type retainers. 2. Remove the screws. 3. Position the LH fender splash shield away from the dash panel. 4. Disconnect the bulkhead electrical connector from inside the fender opening. 1. Loosen the bolt. 2. Disconnect the bulkhead electrical connector. 5. Release the bulkhead electrical connector from the dash panel. 6. Install the LH front wheel and tire assembly. For additional information, refer to Section 204-04. 7. Remove the floor console. For additional information, refer to Floor Console in this section. 8. Remove the upper RH instrument panel support bolt. 9. Disconnect the antenna in-line connector. 10. Disconnect the climate control vacuum harness connector. 11. Close the glove compartment. 12. Remove the LH and RH scuff plates. 13. Remove the LH and RH A-pillar lower trim panels. 1. Remove the pin-type retainers. 2. Remove the A-pillar lower trim panels. 14. Remove the LH and RH windshield side garnish mouldings. If equipped with a convertible top, remove the pin-type retainers. 15. Position the LH and RH door weatherstrips aside. 16. Disconnect the RH main wiring harness electrical connectors. 17. Disconnect the climate control wiring harness connector. 18. Remove the instrument panel steering column cover. 1. Remove the screws. 2. Remove the instrument panel steering column cover. 19. Remove the instrument panel reinforcement. 1. Remove the screws. 2. Remove the instrument panel reinforcement. 20. Separate the intermediate shaft from the steering column shaft. 1. Remove the pinch bolt. 2. Separate the intermediate shaft from the steering column shaft. 21. NOTE: The corner of the carpet may have to be pulled back slightly to carry out this step. Disconnect the LH main wiring harness electrical connectors.

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Actuator Electronic Blend Door Removal 1. Make sure the front wheels are in the straight-ahead position. 2. WARNING: To avoid the risk of serious personal injury, read and follow all warnings, notes and instructions in the deactivation procedure. Deactivate the supplemental restraint system (SRS). For additional information, refer to Section 501-20B. 3. Connect the battery ground cable. 4. Position the front seats rearward. 5. Disconnect the battery ground cable. 6. Through the glove compartment opening, remove the instrument panel support brace bolt. 7. Disconnect the aspirator hose from the housing. 8. Disconnect the RH bulkhead connector. 1. Loosen the bolt. 2. Disconnect the RH bulkhead connector. 9. Close the glove compartment door. 10. Remove the RH lower instrument panel insulator. 1. Disconnect the power point electrical connector. 2. Remove the courtesy lamp from the lamp socket. 3. Remove the RH lower instrument panel insulator. 11. Remove the tunnel brace trim cover. 12. Remove the instrument panel tunnel brace. 1. Remove the nuts. 2. Remove the brace. 13. Position the steering column brace aside. 1. Remove the nut. 2. Position the steering column brace aside. 14. Separate the intermediate shaft from the steering column shaft. 1. Remove and discard the pinch bolt. 2. Separate the intermediate shaft from the steering column shaft. 15. Position the RH and LH cowl side trim panels aside. Position the RH and LH front door weatherstrips aside. 16. Remove the RH and LH A-pillar trim panels. 17. Remove the instrument panel defroster grille. 1. Unclip the instrument panel defroster opening grille. 2. Disconnect the connectors. 3. Remove the instrument panel defroster opening grille. 18. Remove the three instrument panel cowl top screws. 19. Remove the RH instrument panel cowl side nut. 20. Remove the LH instrument panel cowl side nut. 21. Remove the lower instrument panel cowl side bolt.