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Home >> Toyota >> 2004 >> Matrix 4WD L4-1.8L (1ZZ-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Service and Repair >> Part 1

Part 1















OVERHAUL
1. REMOVE REAR WHEEL
2. REMOVE REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (10 mm), remove the filler plug and gasket.
3. REMOVE REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), remove the drain plug and gasket, drain the oil.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
4. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY
SST 09325-20010
5. REMOVE EXHAUST PIPE
6. SEPARATE REAR STABILIZER LINK ASSY LH
7. SEPARATE REAR STABILIZER LINK ASSY RH

HINT: Separate the RH side by the same procedures as LH side

8. REMOVE REAR AXLE SHAFT LH NUT
9. REMOVE REAR AXLE SHAFT RH NUT

HINT: Remove the RH side by the same procedures as LH side

10. REMOVE REAR BRAKE DRUM SUB-ASSY
11. SEPARATE SPEED SENSOR REAR LH
12. SEPARATE SPEED SENSOR REAR RH
13. SEPARATE STRUT SET, PARKING BRAKE SHOE, LH
SST 09703-30010
14. REMOVE FRONT BRAKE SHOE
SST 09718-00010
15. REMOVE STRUT SET, PARKING BRAKE SHOE, LH
16. REMOVE SPRING, TENSION (FOR REAR BRAKE SHOE RETURN)
17. REMOVE REAR BRAKE SHOE
SST 09718-00010
18. REMOVE PARKING BRAKE CABLE ASSY No. 3
19. REMOVE PARKING BRAKE CABLE ASSY No. 2

HINT: Remove the RH side by the same procedures as LH side.

20. SEPARATE REAR BRAKE TUBE No. 4
21. SEPARATE REAR BRAKE TUBE No. 3

HINT: Remove the RH side by the same procedures as LH side.

22. SEPARATE REAR SUSPENSION ARM ASSY No. 1 LH
23. SEPARATE REAR SUSPENSION ARM ASSY No. 1 RH

HINT: Separate the RH side by the same procedures as LH side

24. SEPARATE UPPER CONTROL ARM ASSY
25. REMOVE AXLE ASSY RR LH
26. REMOVE AXLE ASSY RR RH

HINT: Remove the RH side by the same procedures as LH side.

27. REMOVE REAR SUSPENSION MEMBER SUB-ASSY
28. REMOVE REAR DRIVE SHAFT ASSY LH
29. REMOVE REAR DRIVE SHAFT ASSY RH

HINT: Remove the RH side by the same procedures as LH side.

30. REMOVE DIFFERENTIAL CARRIER ASSY REAR
a. Remove the 2 rear mounting bolts.
b. Remove the 2 bolts, nuts and rear differential with support front side.
31. REMOVE DIFFERENTIAL SUPPORT
a. Remove the 3 bolts and differential support rear side from the differential.
32. REMOVE REAR DIFFERENTIAL SUPPORT No. 1
a. Remove the 2 bolts, nuts and differential support front side from the differential.
33. FIX DIFFERENTIAL CARRIER ASSY REAR
34. REMOVE REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (17 mm), remove the rear differential filler plug (inspection plug) and gasket.





35. INSPECT RUNOUT OF TRANSMISSION COUPLING ASSY
a. Using SST and a dial indicator, measure the runout of the transmission coupling vertically.
SST 09564-32011
Maximum runout: 0.05 mm (0.002 inch)
b. Using SST and a dial indicator, measure the runout of the transmission coupling horizontally.
SST 09564-32011
Minimum runout: 0.05 mm (0.002 inch)
36. REMOVE REAR DIFFERENTIAL CARRIER COVER
a. Remove the 4 bolts and differential carrier cover.
37. REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER
38. REMOVE TRANSMISSION COUPLING SPACER





39. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using a screwdriver, remove the dust deflector.

HINT: Tape the screwdriver tip before use.

40. REMOVE TRANSMISSION COUPLING ASSY
a. Remove the transmission coupling assy from the differential carrier cover.





41. REMOVE TRANSMISSION COUPLING RADIAL BALL BEARING
a. Using SST and a press, remove the transmission coupling radial ball bearing No. 1.
SST 09950-00020, 09950-60020 (09951-00910), 09950-70010 (09951-07150)





42. REMOVE TRANSMISSION COUPLING RADIAL BALL BEARING
a. Using SST and a press, remove the transmission coupling radial ball bearing No. 2.
SST 09950-00020, 09950-60010 (09951-00460, 09951-00530, 09952-06010), 09950-70010 (09951-07150)





43. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using SST and a dial indicator, measure the backlash of ring gear while holding the drive pinion.
SST 09556-16011, 09564-32011
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)

NOTICE: Measure at least 3 positions on the circumference of the ring gear.





44. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
SST 09556-16011
Preload (at starting): 0.4 - 0.7 Nm (4 - 7 kgf-cm, 3.0 - 6.0 inch lbs.)

HINT: To make the case bearing smooth, turn clockwise and counterclockwise several times before measuring.

If necessary, disassemble and inspect the differential.





45. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST, remove the 2 oil seals from the housing.
SST 09300-00010
46. REMOVE REAR DRIVE PINION NUT





a. Using SST and a hammer, unstake the nut.
SST 09930-00010

NOTICE: Loosen the staked part of the lock nut completely, otherwise the screw of the drive pinion may be damaged.





b. Using SST to hold the drive pinion, remove the nut.
SST 09564-16020, 09556-16011





47. REMOVE OIL DIAPHRAGM SEAL
a. Using SST, remove the diaphragm oil seal.
SST 09308-10010





48. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the rear drive pinion front tapered roller bearing from the drive pinion.
SST 09556-30010





49. REMOVE HOSE SUB-ASSY, DIFFERENTIAL
a. Remove the 2 clips and hose.





50. REMOVE DIFFERENTIAL PRESSURE CONTROL HOSE ELBOW
a. Place matchmarks on the elbow and differential carrier.
b. Using a screwdriver, remove the 2 elbows.

HINT: Tape the screwdriver tip before use.

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