25TC10 Service Bulletin/Repair Instructions

TECHNICAL INSTRUCTIONS

FOR

SPECIAL SERVICE CAMPAIGN 25TC10
Rear Suspension Member Reduced Corrosion Resistance

CERTAIN 2025 Model Year Corolla
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians

performing this repair are required to successfully complete the most current version of the E-Learning

course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair

performed correctly, technicians performing this recall repair are required to complete the following

course:

•
T4535 – Steering and Suspension
It is the dealership’s responsibility to select technicians with the above course completed to perform this

repair. Carefully review

your resources, the technician skill level, and ability before assigning

technicians to this repair. It is important to consider technician days off and vacation schedules to

ensure there are properly trained technicians available to perform this repair at all times.
I.
OPERATION FLOW CHART
The flow chart is for reference only. DO NOT use it in place of the full technical instructions. Follow ALL

steps as outlined in the full technical instructions to confirm the campaign is completed correctly.
II. IDENTIFICATION OF AFFECTED VEHICLES

1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY

a. Compare the vehicles VIN to the VIN listed on the Repair Order to ensure they match.

b. Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this recall, and that it has not already

been completed.

NOTICE:

TMNA warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were

previously completed, even by another dealer.
III. PREPARATION

A. Parts

Part Number

51206-02060

90950-A1021

17451-F2010
Description

Rear Suspension Member

Plug, Hole

Gasket, Exhaust Pipe, No.2
Quantity

1

7

1
1
B. TOOLS & EQUIPMENT

• 14mm Socket

• 22mm Socket

• Pole Jacks (2)

• Spring Compressor
•

•

•

•
21mm Socket w/ Protective Sleeve

Torque Wrench

21mm Wrench

22mm Wrench
•

•

•
19mm Socket

Ratcheting Wrench

17mm Socket
IV. BACKGROUND

Due to improper paint application, the corrosion resistance of the rear suspension member may be reduced over time.
Rear

Suspension

Member
V. REPAIR PROCEDURE
I. REMOVAL PROCEDURE

1. REMOVE REAR WHEELS

a. Place the vehicle on a lift and lift the vehicle.

b. Using a 21mm socket, remove the driver rear and passenger rear

wheels.

c. Place the wheel in a safe location to avoid a tripping hazard.
2
2.
INSTALL POLE JACK UNDER THE FRONT AND REAR OF

VEHICLE

a. Install pole jacks under the front and rear to provide support during

the repair.
3. REMOVE TAIL EXHAUST ASSEMBLY

a. Using a 14mm socket, remove the (4) exhaust hangers and (2)

exhaust bolts.
4. SEPARATE REAR FLEXIBLE HOSE BRACKET LH AND RH

a. Using a 14mm socket, remove the bolt and separate the rear

flexible hose LH from the rear flexible hose bracket.
b.
Repeat process for the RH side.
3
5. REMOVE REAR STABILIZER BAR SUB-ASSEMBLY

a. Using a 14mm socket, remove the (4) bolts, rear stabilizer bar, (2)

rear No. 1 stabilizer bar brackets, and (2) rear stabilizer bushings from

the rear suspension member sub-assembly.

b. Pivot the stabilizer bar down to allow access for suspension

member removal
•
Use caution when compressing the spring assembly.
6. REMOVE REAR COIL SPRINGS LH AND RH

a. Using the spring compressor, compress the coil spring.

NOTE: Be sure to maintain all safety standards when using spring

compressor. Refer to the instructions for your spring compressor tool.

b. Using a screw jack, support the rear LH No. 2 suspension arm

assembly.

c. Using a 14mm socket, loosen the nut (rear suspension member

sub-assembly side) of the rear No. 2 suspension arm assembly.

d. Remove the bolt and nut and separate the rear No. 2 suspension

arm assembly from the rear axle carrier sub-assembly.

e. Slowly lower the rear No. 2 suspension arm assembly using the

screw jack.

f. Repeat for RH side.
7.
REMOVE THE REAR NO. 2 SUSPENSION ARM

ASSEMBLY LH AND RH

a. Using a 19mm socket, remove the nut for the LH No. 2 camber

adjust cam, rear suspension toe adjust cam sub-assembly, and

rear No. 2 suspension arm assembly.

b. Repeat for RH side.

HINT: Hold the rear suspension toe adjust cam sub-assembly while

rotating the nut.
4
8.
REMOVE REAR NO.1 SUSPENSION ARM ASSEMBLY LH

AND RH

a. Using a 14mm wrench, 14mm socket, remove the (2) bolts,(2)

nuts, and rear No. 1 suspension arm assembly from the rear axle

carrier sub-assembly and rear suspension member sub-assembly.

b. Repeat for RH side.
9.
SEPARATE REAR UPPER CONTROL ARM ASSEMBLY LH

AND RH

a. Using a 14mm socket, remove the bolt and nut and separate the

rear upper control arm assembly LH from the rear axle carrier subassembly LH.

b. Repeat for RH side.
10. REMOVE THE REAR SUSPENSION MEMBER

a. Using a lift table and (4) attachments or equivalent tools, support

the rear suspension member sub-assembly as shown in the

illustration.

b. Using a 22mm socket, remove the (2) bolts and (2) nuts.

c. Slowly lower the rear suspension member sub-assembly.
11. REMOVE REAR UPPER CONTROL ARM ASSEMBLY LH

AND RH

a. Using a 14mm socket, remove the bolt, nut, and rear upper control

arm assembly LH from the rear suspension member subassembly.

b. Repeat for RH side.
5
12. REMOVE REAR SUSPENSION MEMBER HOLE COVERS

a. Remove the (4) rear suspension member hole covers from the

rear suspension member sub-assembly as shown in the

illustration.

• A = LH Side

• B = RH Side
II.
INSTALLATION PROCEDURE

1.
INSTALL THE NEW HOLE PLUGS ONTO THE NEW REAR

SUSPENSION MEMBER

a. Install the (7) new hole plugs onto the rear suspension member

assembly as shown in the illustration.
2.
REINSTALL THE HOLE COVERS TO THE REAR SUSPENSION

MEMBER

a. Remove the (4) rear suspension member hole covers from the rear

suspension member sub-assembly as shown in the illustration.

•

•
A = LH Side

B = RH Side
6
3.
INSTALL REAR UPPER CONTROL ARM ASSEMBLY LH AND

RH

a. Temporarily install the rear upper control arm assembly LH to the

rear suspension member sub-assembly with the bolt and nut.

b. Position the rear upper control arm assembly LH as shown in the

illustration.
•
Reference Length (A): 1.2 mm (0.0472 in.)
•
Torque: 73 N·m {54 ft·lbf}
c.
Repeat for RH side.
•
Reference Length (A): 1.2 mm (0.0472 in.)
•
Torque: 73 N·m {54 ft·lbf}
7
4. INSTALL REAR SUSPENSION SUBMEMBER

a. Using a lift table and (4) attachments or equivalent tools, support

the rear suspension member sub-assembly as shown in the

illustration.

b. Raise the rear suspension member sub-assembly until there is no

clearance between the rear suspension member sub-assembly and

the vehicle.

c. Using a 22mm socket, reinstall the rear suspension member subassembly with the (2) bolts and (2) nuts.

•
Torque: 143 N·m {105 ft·lbf}
5.
TEMPORARILY INSTALL THE REAR UPPER CONTROL

ARM ASSEMBLY LH AND RH

a. Temporarily install the rear upper control arm assembly LH to the

rear axle carrier sub-assembly LH with the bolt and nut.
b.
Repeat for RH side.
6.
TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM

ASSEMBLY LH AND RH

a. Temporarily install the rear No. 1 suspension arm assembly to the

rear axle carrier sub-assembly and rear suspension member subassembly with the (2) bolts and (2) nuts.
8
b.
Repeat for RH side.
7.
TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM

ASSEMBLY LH SIDE

a. Using a 19mm socket, temporarily install the rear No. 2 suspension

arm assembly to the rear suspension member sub-assembly with

the No. 2 camber adjust cam, rear suspension toe adjust cam subassembly, and nut.
•
Use caution when compressing the spring assembly.
8. INSTALL REAR COIL SPRING LH SIDE

a. Set the rear coil spring into the lower perch of the rear No. 2 suspension arm assembly using the

spring compressor.

b. Using a screw jack, slowly raise the rear No. 2 suspension arm assembly being careful not to lift the

vehicle and temporarily install the rear No. 2 suspension arm assembly to the rear axle carrier subassembly with the bolt and nut.

NOTE:

• Set the rear coil spring so that its lower end is within the range shown in the illustration.

• Set the rear coil spring so that the identification mark is positioned as shown in the illustration.

• The smaller diameter end must be at the top.
9
9. STABILIZE SUSPENSION

a. Using the spring compressor and screw jack apply load to the

suspension so that the rear No. 2 suspension arm assembly is

positioned as shown in the illustration.

•
Standard Length (A): 13 mm (0.512 in.)
NOTE: When using a screw jack and raising the rear No. 2

suspension arm assembly, be sure to raise it slowly. Be

careful not to lift the vehicle.
10. INSTALL REAR NO. 2 SUSPENSION ARM LH SIDE

a. Using a 14mm socket, reinstall the rear No. 2 suspension arm

assembly (rear axle carrier sub-assembly side) with the bolt.

•
Torque: 73 N·m {54 ft·lbf}
10
11. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH

SIDE

a. Using a 14mm socket, reinstall the rear No. 1 suspension arm

assembly with the (2) bolts.

•
Torque: 73 N·m {54 ft·lbf}
12. INSTALL REAR UPPER CONTROL ARM ASSEMBLY LH

SIDE

a. Using a 14mm socket, reinstall the rear upper control arm

assembly LH to the rear axle carrier sub-assembly LH with the bolt.

•
Torque: 73 N·m {54 ft·lbf}
13. REMOVE SPRING COMPRESSOR

a. Remove the spring compressor from the LH side and move to the

RH side.
14. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM

ASSEMBLY RH SIDE

a. Using a 19mm socket, temporarily install the rear No. 2 suspension

arm assembly to the rear suspension member sub-assembly with

the No. 2 camber adjust cam, rear suspension toe adjust cam subassembly, and nut.
•
Use caution when compressing the spring assembly.
11
15. INSTALL REAR COIL SPRING RH SIDE

a. Set the rear coil spring to the rear No. 2 suspension arm assembly using the spring compressor.

b. Using a screw jack, slowly raise the rear No. 2 suspension arm assembly being careful not to lift the

vehicle and then temporarily install the rear No. 2 suspension arm assembly to the rear axle carrier

sub-assembly with the bolt and nut.

NOTE:

• Set the rear coil spring so that its lower end is within the range shown in the illustration.

• Set the rear coil spring so that the identification mark is positioned as shown in the illustration.

The smaller diameter end must be at the top.
16. STABILIZE SUSPENSION

a. Using the spring compressor and screw jack, apply load to the

suspension so that the rear No. 2 suspension arm assembly is

positioned as shown in the illustration.

•
Standard Length (A): 13 mm (0.512 in.)
NOTE: When using a screw jack and raising the rear No. 2

suspension arm assembly, be sure to raise it slowly. Be careful not to

lift the vehicle.
12
17. INSTALL REAR NO. 2 SUSPENSION ARM RH SIDE

a. Using a 14mm socket, reinstall the rear No. 2 suspension arm

assembly (rear axle carrier sub-assembly side) with the bolt.

•
Torque: 73 N·m {54 ft·lbf}
18. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH

SIDE

a. Using a 14mm socket, reinstall the rear No. 1 suspension arm

assembly with the (2) bolts.

•
Torque: 73 N·m {54 ft·lbf}
19. INSTALL REAR UPPER CONTROL ARM ASSEMBLY RH

SIDE

a. Using a 14mm socket, reinstall the rear upper control arm

assembly LH to the rear axle carrier sub-assembly LH with the bolt.

•
Torque: 73 N·m {54 ft·lbf}
20. REMOVE SPRING COMPRESSOR

a. Remove the Spring compressor from the RH side.
13
21. INSTALL REAR STABILIZER BAR SUB-ASSEMBLY

a. Using a 14mm socket, reinstall the rear stabilizer bar, (2) rear No. 1

stabilizer bar brackets, and (2) rear stabilizer bushings to the rear

suspension member sub-assembly with the (4) bolts.

•
Torque: 78 N·m {58 ft·lbf}
22. INSTALL REAR FLEX HOSE LH SIDE

a. Using a 14mm socket, reinstall the rear flexible hose to the rear

flexible hose bracket with the bolt.

•
Torque: 29 N·m {21 ft·lbf}
b.

•
Repeat for RH side.
Torque: 29 N·m {21 ft·lbf}
14
23. INSTALL TAIL EXHAUST PIPE ASSEMBLY

a. Install the new exhaust gasket on the front exhaust pipe assembly.

Ensure new exhaust gasket is flush with front of exhaust pipe

flange.

b. Connect the tail exhaust pipe assembly to the (4) exhaust pipe

supports.

c. Install the tail exhaust pipe assembly to the front exhaust pipe

assembly with the (2) bolts and (2) compression springs.
24. REMOVE POLE JACKS

a.

Remove front and rear pole jacks.
25. INSTALL WHEEL AND TIRE ASSEMBLY

a. Fully tighten the hub nuts in the order shown in the illustration.

•
Torque: 103 N·m {76 ft·lbf}
15
26. PERFORM ALIGNMENT FOLLOWING REPAIR MANUAL

a.

Follow the link for the repair manual alignment

procedure.

•
−

−

−

−
2025 Corolla
◄ VERIFY REPAIR QUALITY ►

Confirm hole plugs and hole covers are installed correctly.

Confirm fasteners are torqued to proper specifications.

Confirm vehicle alignment is performed according to repair manual.

If you have any questions regarding this Campaign, please contact your regional representative.
VI. APPENDIX

A.
CAMPAIGN DESIGNATION DECODER
Examples:

19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019

20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020

21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021
16

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