Canada - Steering - Clunk/Pop Noise When Turning

Bulletin
TSB3248

Issue Date
September 3, 2009

Market
Canada

Title
STEERING INTERMEDIATE SHAFT KNOCKING NOISE

Component
STEERING

Models
'09-'10 Corolla; Matrix

INTRODUCTION:
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.





APPLICABILITY:






PRODUCTION CHANGE INFORMATION:
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.






WARRANTY INFORMATION:






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.







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 confirm that the steering wheel is centered.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.