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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 791 (MANUAL TRANSMISSION)OUTPUT 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 2004 Lexus IS 300. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

INSTALL NO. 1 AND NO. 2 CLUTCH HUBS INTO HUB SLEEVE
1. Install the 3 shifting key springs to the clutch hub.
2. While pushing the shifting key spring with a screwdriver, install the 3 shifting keys.
  
  Fig 1: Installing Shifting Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. While pushing the 3 shifting keys, install the clutch hub to the hub sleeve, as shown in Fig 2 .
  
  Fig 2: Installing Clutch Hub To Hub Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD GEAR AND NO. 2 CLUTCH HUB ON OUTPUT SHAFT
1. Apply gear oil to the shaft.
2. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
  
  Fig 3: Aligning Ring Slots With Shifting Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a press, install the 3rd gear and No. 2 clutch hub.
  
  Fig 4: Installing 3rd Gear & No. 2 Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SNAP RING
1. Select a snap ring that will allow minimum axial play.
  
  Fig 5: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, install the snap ring.
INSPECT 3RD GEAR THRUST CLEARANCE (See DISASSEMBLY )
INSTALL 2ND GEAR AND NO. 1 CLUTCH HUB
1. Apply gear oil to the shaft and needle roller bearing.
2. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
3. Install the needle roller bearing in the 2nd gear.
  
  Fig 7: Aligning Ring Slots With Shifting Key
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a press, install the 2nd gear and No. 1 clutch hub.
Fig 8: Installing 2nd Gear & No. 1 Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND GEAR THRUST CLEARANCE (See DISASSEMBLY )
INSTALL LOCKING BALL AND 1ST GEAR ASSEMBLY
1. Install the locking ball in the shaft.
2. Apply gear oil to the bearing.
3. Assemble the 1st gear, synchronizer ring, needle roller bearing and bearing inner race.
4. Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys and turn the inner race to align it with the locking ball.
Fig 9: Aligning Synchronizer Ring Slots With Shifting Keys
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT CENTER BEARING
Using SST and a press, install the center bearing on the output shaft with the outer race snap ring groove toward the rear.

HINT:

Hold the 1st gear inner race to prevent it from falling.
1. SST 09506-35010
INSPECT 1ST GEAR THRUST CLEARANCE (See DISASSEMBLY )

Fig 10: Installing Output Shaft Center Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002