Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 197 (OVERHAUL - W55)COMPONENT DISASSEMBLY & REASSEMBLYOUTPUT SHAFTREASSEMBLY
2004 Toyota Matrix XR, FWD, Standard
Output Shaft: Reassembly
2004 Toyota Matrix XR, FWD, StandardSECTION Reassembly
WARNING: This page is about a different car, the 2003 Lexus IS 300 and 2002 Lexus IS 300. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
Coat all parts with gear oil before assembly.
- Install 3 shifting key springs to clutch hub. While pushing shifting key spring with a screwdriver, install 3 shifting keys. While pushing 3 shifting keys, install clutch hub to hub sleeve. Apply gear oil to shaft. Place synchronizer ring on gear and align ring slots with shifting keys. See Fig 2. Using a press, install 3rd gear and No. 2 clutch hub. Select and install snap ring that will allow minimal axial play. See OUTPUT SHAFT FRONT SNAP RING SPECIFICATIONS table.
- Measure 3rd gear thrust clearance. See Figure. Standard clearance is .004-.010" (.10-.25 mm). Maximum clearance is .010" (.25 mm). Apply gear oil to shaft and needle roller bearing. Place synchronizer ring on 2nd gear and align ring slots with shifting keys. See Fig 2. Install needle roller bearing in 2nd gear. Support No. 1 clutch hub with press and install 2nd gear and No. 1 hub with sleeve on output shaft. See Fig 1. Measure 2nd gear thrust clearance. Standard clearance is .004-.010" (.10-.25 mm). Maximum clearance is .010" (.25 mm).
- Install locking ball in output shaft. Apply gear oil to bearing. Assemble 1st gear, synchronizer ring, needle roller bearing and bearing inner race. Install 1st gear assembly on output shaft with synchronizer ring slots aligned with shifting keys. See Fig 2. Turn inner race to align it with locking ball.
- Press rear bearing on output shaft with outer race snap ring groove toward rear. Ensure 1st gear inner race remains in correct position while pressing on bearing. Press 5th gear on end of output shaft. Measure 1st gear thrust clearance. Standard clearance is .004-.010" (.10-.25 mm). Maximum clearance is .010" (.25 mm).
OUTPUT SHAFT FRONT SNAP RING SPECIFICATIONS
| ID Stamp | Thickness - In. (mm) |
|---|---|
| C-1 | .069-.071 (1.75-1.80) |
| D | .071-.073 (1.80-1.85) |
| 11 | .073-.075 (1.85-1.91) |
| 12 | .076-.078 (1.92-1.97) |
| 13 | .078-.080 (1.98-2.03) |
| 14 | .080-.082 (2.04-2.09) |
| 15 | .083-.085 (2.10-2.15) |
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.