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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 180 (AUTOMATIC TRANSMISSION OVERHAUL - U140F)COMPONENT DISASSEMBLY & REASSEMBLYDIFFERENTIAL ASSEMBLYREASSEMBLY
2004 Toyota Matrix XR, FWD, Standard

Differential Assembly: Reassembly

2004 Toyota Matrix XR, FWD, StandardSECTION Reassembly
WARNING: This page is about a different car, the 2005 Toyota RAV4, 2004 Toyota RAV4, 2003 Toyota RAV4, 2002 Toyota RAV4, and 2001 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Coat all sliding and rotating surfaces with ATF prior to reassembly.
  1. Using appropriate race installer and a hammer, install transaxle housing bearing race. Install plate washer of lesser thickness than washer removed during disassembly into transaxle case. Using appropriate race installer and a hammer, install transaxle case bearing race. See Figure.
  2. Coat front differential side gear thrust washer, front differential side gear, front differential pinion shaft holder, 4 front differential pinion thrust washers and 4 front differential pinion gears with ATF, and install components into front differential case. Install 3 pinion shafts into front differential case. See Figure.
  3. Mount front differential case in soft-jawed vise. DO NOT damage surface of front differential case which contacts vise. Using a dial indicator, measure front differential pinion gear backlash while holding front differential side gear toward front differential case. See Fig 1.
  4. Backlash should be .002-.008" (.05-.20 mm). If backlash is not within specification, select appropriate thrust washer to ensure backlash is within specification. Thrust washers are marked in alphabetical order from "B" to "G", and are available in thicknesses from .039" (1.00 mm) to .049" (1.25 mm) in increments of .002"(.05 mm).
    Fig 1: Measuring Front Differential Pinion Gear Backlash
    G00011289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Engage side gear to front differential case. Install left side differential case to front differential case. Ensure side gear is centered. Once side gear is centered, remove left side differential case.
  6. Using a straightedge and feeler gauge, measure clearance between front differential case and side gear. See Fig 2. Use the following formula to determine correct thrust washer thickness for specified clearance: thrust washer thickness equals clearance (feeler gauge thickness) minus .006-.011" (.16-.27 mm).
  7. Thrust washers are marked in alphabetical order from "A" to "K" (except "I"), and are available in thicknesses from .037" (.95 mm) to .055" (1.40 mm) in increments of .002" (.05 mm). If clearance is not as specified, ensure components were assembled correctly.
    Fig 2: Measuring Front Differential Case-To-Side Gear Clearance
    G00011290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Install spacer to front differential case. Wrap vinyl tape around case prior to snap ring installation to avoid damaging front differential case. Install snap ring on front differential case as shown. See Fig 3. Install spacer to right side differential case. Slide down spacer to install 4 center differential pinion shafts.
  9. Install center differential side gear thrust washer No. 1, conical washer, center differential side gear, pinion shaft holder, differential pinion gears, thrust washers and pinion shafts to right side differential case. Ensure conical washer is installed correctly into right side differential case. See Figure. Mount right side differential case in soft-jawed vise. Using dial indicator, measure center differential pinion gear backlash, while holding center differential side gear toward case. See Fig 4.
  10. Backlash should be .002-.008" (.05-.20 mm). If backlash is not within specification, select appropriate thrust washer to ensure backlash is within specification. Thrust washers are marked in alphabetical order from "MA" to "MN" (except "MI"), and are available in thicknesses from .032" (.80 mm) to .055" (1.40 mm) in increments of .002" (.05 mm).
    Fig 3: Installing Snap Ring To Front Differential Case
    G00182315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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