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Home >> Toyota >> 2006 >> Matrix 2WD L4-1.8L (2ZZ-GE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Overhaul (Transmission) >> Manual Transmission Unit >> Part 2

Part 2

OVERHAUL Continued





52. REMOVE FRONT TRANSAXLE CASE OIL SEAL
a. Using SST, remove the front transaxle case oil seal from the transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)





53. REMOVE OUTPUT SHAFT FRONT BEARING
a. Using SST, remove the output shaft front bearing from the transaxle case.
SST 09308-00010

NOTICE: Do not apply excessive force to the transaxle case when installing it.





54. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST, remove the front differential case rear tapered roller bearing (outer race) and shim from the manual transmission case.
SST 09612-65014 (09612-01040, 09612-01050)





b. Using SST, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.
SST 09612-65014 (09612-01040, 09612-01050), 09950-40011 (09951-00390, 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010





55. REMOVE TRANSMISSION CASE OIL SEAL
a. Using SST and a hammer, remove the transmission case oil seal from the manual transmission case.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)





56. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Using SST, remove the front differential case front tapered roller bearing (outer race) and front differential case front plate washer from the transaxle case.
SST 09612-65014 (09612-01040, 09612-01050)





b. Using SST, remove the FR differential case front tapered roller bearing (inner race) from the front differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00390)





57. REMOVE TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, remove the transaxle case oil seal from the transaxle case.
SST 09950-60010 (09951-00600), 09950-70010 (09951-07100)





58. REMOVE OUTPUT SHAFT (MTM) COVER
a. Remove the output (MTM) shaft cover from the transaxle case.





59. REMOVE TRANSMISSION HUB SLEEVE NO.3
a. Remove the transmission hub sleeve No.3, 3 synchromesh shifting key No.3 and 2 synchromesh shifting key spring No.3.

NOTICE: Use a shop rag to keep the synchromesh shifting keys and springs from flying.





60. INSPECT TRANSMISSION HUB SLEEVE NO.3
a. Check the sliding condition between the transmission hub sleeve No.3 and transmission clutch hub No.3.
b. Check that the tip of the spline gear of the transmission hub sleeve No.3 is not worn down.





c. Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove (A) and the thickness of the claw part on the gear shift fork No.3 (B), and calculate the clearance.
Standard clearance (A - B): 0.31 to 0.89 mm (0.0122 to 0.035 inch)
If the clearance is out of specification, replace the transmission hub sleeve No.3 and gear shift fork No.3.





61. INSPECT SYNCHRONIZER RING NO.3 (FOR 6TH GEAR MT)
a. Check for wear or damage.
b. Coat the 6th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 6th gear cone. Check that the ring locks.
If the synchronizer outer ring does not lock, replace the ring or the 6th gear.





c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.065 inch)
If the clearance is out of specification, replace the synchronizer ring No.3.





62. INSPECT 6TH GEAR SUB-ASSEMBLY
a. Using a caliper gauge, measure the 6th gear inner diameter.





Inner diameter

If the clearance exceeds the maximum, replace the 6th gear sub-assembly.





63. INSPECT SYNCHRONIZER RING NO.3 (FOR 5TH GEAR MT)
a. Coat the 5th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone. Check that the ring locks.
If the synchronizer outer ring does not lock, replace the ring or the 5th gear.





b. Using a feeler gauge, measure the clearance between the synchronizer ring back and 5th gear spline end.
Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.0650 inch)
If the clearance is out of specification, replace the synchronizer ring No.3.





64. INSPECT 5TH GEAR
a. Using a caliper gauge, measure the 5th gear inner diameter.





Inner diameter

If the inner diameter exceeds the maximum, replace the 5th gear.





65. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
a. Using a caliper gauge, inspect the reverse idler gear sub-assembly as shown in the illustration.





Inner diameter

If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assembly.
b. Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.





Outer diameter

If the outer diameter is less than the minimum, replace the reverse idler gear shaft.





66. INSTALL TRANSMISSION HUB SLEEVE NO.3
a. Coat the transmission hub sleeve No.3 with gear oil, and install it to the transmission clutch hub No.3.

NOTICE: Do not set the transmission clutch hub No.3 in an incorrect orientation.

b. Using a screwdriver, install the 2 synchromesh shifting key spring No.3 and 3 synchromesh shifting key No.3.

NOTICE: Do not set the openings of the shifting key springs in the same position.





67. INSTALL OUTPUT SHAFT (MTM) COVER
a. Coat the output shaft (MTM) cover with MP grease, and install it to the transaxle case.





68. INSTALL TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install the transaxle case oil seal to the transaxle case.
SST 09726-27012 (09726-02041), 09950-70010 (09951-07100)
Driven in depth: 1.6 to 2.2 mm (0.063 to 0.087 inch)





69. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
a. Using SST and a press, install the FR differential case front tapered roller bearing (inner race) to the front differential case.
SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)





b. Using SST and a press, install the front differential case front plate washer and FR differential case front tapered roller bearing (outer race) to the transaxle case.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)





70. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
a. Using SST and a press, install the FR differential case rear tapered roller bearing (inner race) to the front differential case.
SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)





b. Using SST and a press, install the front differential case rear plate washer and FR differential case rear tapered roller bearing (outer race) to the manual transmission case.
SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)





71. INSTALL OUTPUT SHAFT FRONT BEARING
a. Coat a new output shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case. SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)





72. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
a. Coat the differential case assembly with gear oil, and install it to the transaxle case.
b. Install the manual transmission case with the 16 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





c. Using SST and a torque wrench, turn the deferential case assembly right and left 2 or 3 times to allow the bearings to settle. SST 09564-32011





d. Using SST and a torque wrench, measure the preload.
SST 09564-32011





Preload

If the preload is out of specification, select a proper front differential case rear plate washer and adjust it.

HINT:








Washer thickness

e. Remove the 16 bolts and manual transmission case. Remove the differential case assembly from the transaxle case.





73. INSTALL FRONT TRANSAXLE CASE OIL SEAL
a. Using SST and a hammer, install a new front transaxle case oil seal to the transaxle case.
SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)
Driven in depth: 15.6 to 16.0 mm (0.6142 to 0.6299 inch)
b. Coat the lip of the front transaxle case oil seal with MP grease.





74. INSTALL INPUT SHAFT FRONT BEARING
a. Coat a new input shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.
SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
Driven in depth: 0 to 0.30 mm (0 to 0.0118 inch)





75. INSTALL TRANSMISSION MAGNET
a. Clean the transmission magnet, and install it to the transaxle case.





76. INSTALL BEARING LOCK PLATE
a. Install the bearing lock plate with the bolt to the transaxle case.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)





77. INSTALL MANUAL TRANSAXLE CASE RECEIVER
a. Install the manual transaxle case receiver with the bolt to the transaxle case.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)





78. INSTALL DIFFERENTIAL CASE ASSEMBLY
a. Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the transaxle case.





79. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
a. Install the reverse shift arm bracket assembly with the 2 bolts to the transaxle case.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)





80. INSTALL INPUT SHAFT ASSEMBLY
a. Coat the sliding and rotating surfaces of the input and output shafts with gear oil, and install them to the transaxle case.





81. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
a. Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them to the transaxle case.

HINT: Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.





82. INSTALL GEAR SHIFT FORK SHAFT NO.2
a. Coat the gear shift fork No.2 and gear shift fork No.1 with gear oil, and install them to the input and output shafts.





b. Coat the gear shift fork shaft No.2 with gear oil, and install the gear shift head No.1, reverse shift fork and gear shift fork shaft No.2.





c. Coat the 2 shift lock bolts with sealant, and install them to the gear shift fork No.2 and gear shift head No.1.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
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