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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 911 (MANUAL TRANS)MANUAL TRANSAXLE ASSY (E351)OVERHAUL

2004 Toyota Matrix XR, FWD, Standard

Manual Transaxle ASSY (E351): Overhaul

2004 Toyota Matrix XR, FWD, StandardSECTION Overhaul

WARNING: This page is about a different car, the 2004 Toyota Camry Solara. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE CLUTCH RELEASE FORK SUB-ASSY
1. Remove the clutch release fork sub-assy together with the clutch release bearing assy from the manual transaxle case.
  
  Fig 1: Removing Clutch Release Fork Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH RELEASE BEARING ASSY
1. Remove the clutch release bearing assy and release bearing hub clip from the clutch release fork subassy.
REMOVE RELEASE FORK SUPPORT
1. Remove the release fork support from the manual transaxle case.
  
  Fig 2: Removing Release Fork Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH RELEASE FORK BOOT
1. Remove the clutch release fork boot from the manual transaxle case.
REMOVE SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSY
1. Remove the bolt and speedometer driven (MTM) gear sub-assy.
2. Remove the MTM speedometer shaft sleeve clip, and remove the speedometer driven gear from the speedometer sensor.
REMOVE SELECTING BELL CRANK ASSY
1. Remove the 2 bolts and selecting bell crank assy from the manual transmission case.
  
  Fig 3: Removing Selecting Bell Crank Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL SHIFT LEVER
1. Remove the nut and spring washer.
  
  Fig 4: Removing Spring Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, remove the shift outer lever lock pin.
  
  Fig 5: Removing Shift Outer Lever Lock Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the control shift lever.
REMOVE CONTROL SHAFT COVER
1. Remove the 4 bolts and control shaft cover from the manual transmission case.
  
  Fig 6: Removing Control Shaft Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FIX MANUAL TRANSAXLE ASSY
1. Place the manual transaxle assy on wooden blocks.
  
  Fig 7: Fixing Manual Transaxle Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOCK BALL ASSY NO. 1
1. Remove the lock ball assy No. 1 from the manual transmission case.
  
  Fig 8: Removing Lock Ball Assembly No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION BREATHER PLUG
1. Remove the manual transmission breather plug and gasket.
  
  Fig 9: Removing Manual Transmission Breather Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT & SELECT LEVER SHAFT ASSY
1. Remove the shift & select lever shaft assy from the manual transmission case.
  
  Fig 10: Removing Shift & Select Lever Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK UP LAMP SWITCH ASSY
1. Remove the back up lamp switch assy and gasket from the manual transmission case.
  
  Fig 11: Removing Back Up Lamp Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION FILLER PLUG
1. Remove the manual transmission filler plug and gasket from the manual transmission case.
  
  Fig 12: Removing Manual Transmission Filler Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRAIN (MTM) PLUG SUB-ASSY
1. Remove the drain (MTM) plug sub-assy and gasket from the manual transmission case.
  
  Fig 13: Removing Drain (MTM) Plug Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSY
1. Remove the 10 bolts and manual transmission case cover from the manual transmission case.
  
  Fig 14: Removing Manual Transmission Case Cover Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
1. Double mesh the gears. (Engage 1st and 2nd gears simultaneously.)
  
  Fig 15: Double Meshing Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, unstake the manual transmission output shaft rear set nut.
  SST 09930-00010
  
  Fig 16: Unstaking Manual Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, remove the manual transmission output shaft rear set nut from the output shaft.
  SST 09229-55010
  
  Fig 17: Removing Manual Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disengage the gears.
INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, inspect the 5th gear thrust clearance.
  Standard clearance: 0.10 to 0.65 mm (0.0039 to 0.0256 in.)
  
  If clearance is out of specification, replace the transmission clutch hub No. 3, 5th gear or input shaft rear radial ball bearing.
  
  Fig 18: Inspecting 5th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, inspect the 5th gear radial clearance.
  Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 in.)
  
  If clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.
  
  Fig 19: Inspecting 5th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION CLUTCH HUB NO. 3
1. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.
  
  Fig 20: Removing Transmission Clutch Hub No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Cover with a shop rag to keep the snap ring from flying.
2. Remove the shift fork set bolt from the gear shift fork No. 3.
  
  Fig 21: Removing Shift Fork Set Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, remove the transmission clutch hub No. 3 and gear shift fork No. 3 from the input shaft.
  SST 09950-30012 (09951-03010, 09953-03010, 09954-03010), 09950-50013 (09957-04010), 09950-60010 (09951-00280)
  
  Fig 22: Removing Transmission Clutch Hub No. 3 & Gear Shift Fork No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 5TH GEAR
1. Remove the 5th gear from the input shaft.
  
  Fig 23: Removing 5th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 5TH GEAR NEEDLE ROLLER BEARING
1. Remove the 5th gear needle roller bearing from the input shaft.
  
  Fig 24: Removing 5th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 5TH DRIVEN GEAR
1. Using SST, remove the 5th driven gear from the output shaft.
  SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09957-04010), 09950-60010 (09951-00180, 09955-03011), 09950-50013
  
  Fig 25: Removing 5th Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING RETAINER REAR (MTM)
1. Using a torx socket wrench (T45), remove the 7 torx screws and bearing retainer rear (MTM) from the manual transmission case.
  
  Fig 26: Removing Bearing Retainer Rear (MTM)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT REAR BEARING SHIM
1. Remove the output shaft rear bearing shim from the output shaft.
  
  Fig 27: Removing Output Shaft Rear Bearing Shim
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING
1. Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.
  
  Fig 28: Removing Input Shaft Rear Bearing Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT FORK SHAFT SNAP RING
1. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No. 1.
  HINT:
  
  Cover with a shop rag to keep the snap ring from flying.
  
  Fig 29: Removing Shift Fork Shaft Snap Ring From Gear Shift Fork Shaft No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No. 2.
  HINT:
  
  Cover with a shop rag to keep the snap ring from flying.
  
  Fig 30: Removing Shift Fork Shaft Snap Ring From Gear Shift Fork Shaft No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR SHAFT BOLT
1. Remove the reverse idler gear shaft bolt and gasket.
  
  Fig 31: Removing Reverse Idler Gear Shaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH TUBE BRACKET NO. 1
1. Remove the bolt and clutch tube bracket.
REMOVE MANUAL TRANSMISSION CASE
1. Remove the 3 bolts from the manual transaxle case side.
  
  Fig 32: Removing Manual Transmission Case (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 14 bolts from the manual transmission case side.
  
  Fig 33: Removing Manual Transmission Case (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tapping with a plastic hammer, remove the manual transmission case.
REMOVE OIL RECEIVER PIPE NO. 2 (MTM)
1. Remove the bolt and oil receiver pipe No. 2 (MTM) from the manual transmission case.
  NOTE: Do not damage the pipe.