Canada - Drivetrain - Rear End Whining/Humming/Growling Noises

Bulletin
2829

Issue Date
September 11, 2007

Market
Canada

Title:
ABNORMAL NOISE FROM REAR DIFFERENTIAL

Component
DRIVELINE

Models
'03 - '06 Matrix (AWD/4WD)

INTRODUCTION:
Some customers may complain about an abnormal noise from the rear of the vehicle that increases in volume as vehicle speed increases. The noise is commonly described as a whining, humming, roaring, or growling noise. The source of the noise may be a damaged transmission coupling assembly and 2 ball bearing assemblies. Follow the repair procedure in this TSB to diagnose and repair this condition.

APPLICABLE VEHICLES:
- 2003 - 2006 model year Matrix vehicles equipped with AWD (4WD).

NOTE:
Vehicles towed with two wheels off the ground or driven with mismatched sized tires can display this noise condition. These vehicles are NOT covered under warranty due to the failure by the customer to follow Owner's Manual instructions to prevent damaging the AWD (4WD) system.







PARTS INFORMATION:







WARRANTY INFORMATION:










REQUIRED TOOLS & MATERIAL:







NOTE*:
- Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.







NOTE*:
- A mechanic's stethoscope or similar tool may be used in place of ChassisEAR(TM).
- ChassisEAR(TM) may be ordered by calling Toyota Approved Dealer Equipment Services at 1-866-868-3372.

REPAIR PROCEDURE:
1. Test drive the vehicle and confirm the customer complaint.
2. Isolate the source of the noise using ChassisEAR(TM), mechanic's stethoscope, or similar tool.







Is the noise coming from the area indicated in the illustration?
- If Yes - This TSB applies. Go to step 3.
- If No - STOP - This TSB does NOT apply. Continue diagnosis using the Repair Manual.







3. Replace the Transmission Coupling Assembly, Radial Ball Bearing No. 1, and Radial Ball Bearing No. 2 to repair the vehicle. (Refer to the illustration for the circled parts which are required to be replaced.)

4. Remove the rear differential carrier assembly from the vehicle. Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Matrix
- Year: 2003 - 2005
- Service Category: Drivetrain
- Section: Axle/Differential
- Keyword: Rear Differential Carrier Assy Rear (for 4WD): Overhaul

- Division: Toyota
- Model: Matrix
- Year: 2006
- Service Category: Drivetrain
- Section: Axle/Differential
- Keyword: Rear Differential Carrier Assy Rear (for 4WD): Removal

5. Replace the transmission coupling assembly (viscous coupling), both radial ball bearing assemblies, and rear differential dust deflector using the procedures.
A. Remove the rear differential carrier cover by removing the 4 bolts.
B. Remove the transmission coupling conical spring washer.
C. Remove the transmission coupling spacer.







D. Using a screwdriver, remove the rear differential dust deflector.

HINT:
Tape the screwdriver tip before use.

E. Remove the transmission coupling assembly from the differential carrier cover

6. Reassemble the rear differential carrier assembly







A. Using the SSTs and a press, install the transmission coupling radial ball bearing No. 1.
- SST P/N 09502-12010
- SST P/N 09550-55011 (09550-05061)
- SST P/N 09950-70010 (09951-07150)







B. Using the SSTs and a press, install the transmission coupling radial ball bearing No. 2.
- SST P/N 09223-15030
- SST P/N 09950-70010

C. Install the transmission coupling assembly to the rear differential carrier cover.






D. Using the SSTs and a press, install the NEW rear differential dust deflector.
- SST P/N 09518-36020
- SST P/N 09950-70010 (09951-07150)

E. Install the transmission coupling spacer.
F. Install the transmission coupling conical spring washer.

NOTE:
Install the transmission coupling conical spring washer so that the side marked orange faces to the front of the vehicle (coupling side).

G. Install the rear differential carrier cover with the 4 bolts to the differential carrier.
Torque: 20 N-m (200 kgf-cm, 14 ft-lbf)

7. Install the rear differential carrier assembly in the vehicle.
Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Matrix
- Year: 2003 - 2005
- Service Category: Drivetrain
- Section: Axle/Differential
- Keyword: Rear Differential Carrier Assembly (for 4WD): Overhaul

- Division: Toyota
- Model: Matrix
- Year: 2006
- Service Category: Drivetrain
- Section: Axle/Differential
- Keyword: Differential Rear Differential Carrier Assembly (for 4WD): Installation

8. Test drive the vehicle and confirm the vehicle is repaired.