Toyota Matrix 2003-06

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Place the front wheels in the straight-ahead position.
  6.  
  7. Remove or disconnect the following:

    Steering intermediate shaft
     
    Front wheel and tires
     
    Right and left side undercovers
     
    Exhaust pipe
     
    Hood
     
    Cylinder head (valve) cover
     
    Air cleaner assembly
     
    Battery clamp, battery, battery tray and battery carrier
     
    Cruise control actuator assembly, if equipped
     

  8.  
  9. Remove the wire harness as follows:
    1. Remove the wire harness clamp, 2 bolts and wire harness brackets.
    2.  
    3. Remove the 2 bolts and 2 ground cables.
    4.  

  10.  
  11. Remove or disconnect the following:

    Back-up lamp switch connector, with ABS
     
    Speed sensor connector, without ABS
     
    5 bolts, then separate the release cylinder with the clutch pipes from the transaxle
     
    Shift cable clips and washer, then disconnect the cable from the transaxle and bracket
     
    Select cable clips and washer, then disconnect the cable from the transaxle and bracket
     
    Starter
     
    Right and left side tie rod ends
     
    Pressure feed tube
     
    Front halfshafts
     

  12.  
  13. Use a suitable tool to suspend the engine assembly, as shown in the illustration:
    1. No. 1 engine hanger: P/N 12281-22021 (5-speed M/T), 12281-88600 (6-speed M/T).
    2.  
    3. No. 2 engine hanger: P/N 12281-15040 (5-speed M/T), 12281-88600 (6-speed M/T).
    4.  
    5. Bolt: P/N 91512-B1016.
    6.  
    7. Torque the bolts to 28 ft. lbs. (38 Nm).
    8.  

  14.  


CAUTION
Do not try to suspend the engine by hooking the chain to any other part.

  1. Attach an engine chain hoist to the hangers.
  2.  



Click image to see an enlarged view

Fig. Secure the engine using the proper tools-5-speed manual transmission shown

Secure the engine using the proper tools-5-speed manual transmission shown

Click image to see an enlarged view

Fig. Secure the engine using the proper tools-6-speed manual transmission shown

Secure the engine using the proper tools-6-speed manual transmission shown
  1. Remove or disconnect the following:

    Front suspension crossmember
     

  2.  
  3. Support the transaxle with a floor jack.

    Transverse engine mounting insulator and brackets
     
    Manual transaxle assembly
     


    Click image to see an enlarged view

    Fig. Exploded view of the manual transaxle (1 of 2)

    Exploded view of the manual transaxle (1 of 2)

    Click image to see an enlarged view

    Fig. Exploded view of the manual transaxle (2 of 2)

    Exploded view of the manual transaxle (2 of 2)
    Transverse engine mounting brackets from the transaxle, if necessary
     

  4.  

To install:



Transverse engine mounting brackets to the transaxle, if necessary
 
Manual transaxle, by aligning the input shaft with the clutch disc. Torque the -A- bolts to 47 ft. lbs. (64 Nm), the -B- bolts to 35 ft. lbs. (47 Nm) and the -C- bolts to 17 ft. lbs. (23 Nm).
 


Click image to see an enlarged view

Fig. Manual transaxle bolt installation locations

Manual transaxle bolt installation locations
Transverse engine mounting bracket. Tighten to 38 ft. lbs. (52 Nm).
 
Transverse engine mounting insulator. Tighten the -A- bolts to 38 ft. lbs. (52 Nm) and the -B- bolts to 59 ft. lbs. (80 Nm).
 



Click image to see an enlarged view

Fig. Transverse engine mounting insulator bolt locations

Transverse engine mounting insulator bolt locations
  1. The remainder of installation is the reverse of the removal procedure, noting the following specifications:
    1. Starter mounting bolts: 27 ft. lbs. (37 Nm).
    2.  
    3. Clutch release cylinder bolts: -A- bolts 19 ft. lbs. (25 Nm), -B- bolts 9 ft. lbs. (12 Nm) and -C- bolts 44 inch lbs. (5 Nm).
    4.  


      Click image to see an enlarged view

      Fig. Clutch release cylinder bolt locations

      Clutch release cylinder bolt locations
    5. Battery carrier bolts: 10 ft. lbs. (13 Nm).
    6.  
    7. Battery clamp bolt: 44 inch lbs. (5 Nm).
    8.  
    9. Battery clamp nut: 31 inch lbs. (3.5 Nm).
    10.  
    11. Cylinder head cover bolts: 62 inch lbs. (7 Nm).
    12.  
    13. Hood bolts: 10 ft. lbs. (13 Nm).
    14.  
    15. Wheel lug nuts: 76 ft. lbs. (103 Nm).
    16.  

  2.  
  3. Fill the transaxle fluid to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Place the front wheels in the straight-ahead position.
  6.  
  7. Remove or disconnect the following:

    Steering intermediate shaft
     
    Front wheel and tires
     
    Right and left side undercovers
     
    Exhaust pipe
     
    Hood
     
    Cylinder head (valve) cover
     
    Air cleaner assembly
     
    Battery clamp, battery, battery tray and battery carrier
     
    Cruise control actuator assembly, if equipped
     

  8.  
  9. Remove the wire harness as follows:
    1. Remove the wire harness clamp, 2 bolts and wire harness brackets.
    2.  
    3. Remove the 2 bolts and 2 ground cables.
    4.  

  10.  
  11. Remove or disconnect the following:

    Back-up lamp switch connector, with ABS
     
    Speed sensor connector, without ABS
     
    5 bolts, then separate the release cylinder with the clutch pipes from the transaxle
     
    Shift cable clips and washer, then disconnect the cable from the transaxle and bracket
     
    Select cable clips and washer, then disconnect the cable from the transaxle and bracket
     
    Starter
     
    Right and left side tie rod ends
     
    Pressure feed tube
     
    Front halfshafts
     

  12.  
  13. Use a suitable tool to suspend the engine assembly, as shown in the illustration:
    1. No. 1 engine hanger: P/N 12281-22021 (5-speed M/T), 12281-88600 (6-speed M/T).
    2.  
    3. No. 2 engine hanger: P/N 12281-15040 (5-speed M/T), 12281-88600 (6-speed M/T).
    4.  
    5. Bolt: P/N 91512-B1016.
    6.  
    7. Torque the bolts to 28 ft. lbs. (38 Nm).
      CAUTION
      Do not try to suspend the engine by hooking the chain to any other part.

    8.  
    9. Attach an engine chain hoist to the hangers.

      Click image to see an enlarged view

      Fig. Secure the engine using the proper tools-5-speed manual transmission shown

      Secure the engine using the proper tools-5-speed manual transmission shown

      Click image to see an enlarged view

      Fig. Secure the engine using the proper tools-6-speed manual transmission shown

      Secure the engine using the proper tools-6-speed manual transmission shown
    10.  

  14.  
  15. Remove or disconnect the following:

    Front suspension crossmember
     

  16.  
  17. Support the transaxle with a floor jack.

    Transverse engine mounting insulator and brackets
     
    Manual transaxle assembly

    Click image to see an enlarged view

    Fig. Exploded view of the manual transaxle (1 of 2)

    Exploded view of the manual transaxle (1 of 2)

    Click image to see an enlarged view

    Fig. Exploded view of the manual transaxle (2 of 2)

    Exploded view of the manual transaxle (2 of 2)
     
    Transverse engine mounting brackets from the transaxle, if necessary
     

  18.  

To install:



Transverse engine mounting brackets to the transaxle, if necessary
 
Manual transaxle, by aligning the input shaft with the clutch disc. Torque the -A- bolts to 47 ft. lbs. (64 Nm), the -B- bolts to 35 ft. lbs. (47 Nm) and the -C- bolts to 17 ft. lbs. (23 Nm).

Click image to see an enlarged view

Fig. Manual transaxle bolt installation locations

Manual transaxle bolt installation locations
 
Transverse engine mounting bracket. Tighten to 38 ft. lbs. (52 Nm).
 
Transverse engine mounting insulator. Tighten the -A- bolts to 38 ft. lbs. (52 Nm) and the -B- bolts to 59 ft. lbs. (80 Nm).

Click image to see an enlarged view

Fig. Transverse engine mounting insulator bolt locations

Transverse engine mounting insulator bolt locations
 

  1. The remainder of installation is the reverse of the removal procedure, noting the following specifications:
    1. Starter mounting bolts: 27 ft. lbs. (37 Nm).
    2.  
    3. Clutch release cylinder bolts: -A- bolts 19 ft. lbs. (25 Nm), -B- bolts 9 ft. lbs. (12 Nm) and -C- bolts 44 inch lbs. (5 Nm).

      Click image to see an enlarged view

      Fig. Clutch release cylinder bolt locations

      Clutch release cylinder bolt locations
    4.  
    5. Battery carrier bolts: 10 ft. lbs. (13 Nm).
    6.  
    7. Battery clamp bolt: 44 inch lbs. (5 Nm).
    8.  
    9. Battery clamp nut: 31 inch lbs. (3.5 Nm).
    10.  
    11. Cylinder head cover bolts: 62 inch lbs. (7 Nm).
    12.  
    13. Hood bolts: 10 ft. lbs. (13 Nm).
    14.  
    15. Wheel lug nuts: 76 ft. lbs. (103 Nm).
    16.  

  2.  
  3. Fill the transaxle fluid to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the precautions section.
    CAUTION
    Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

  2.  
  3. Remove the battery and tray.
  4.  
  5. Remove the air cleaner case assembly.
  6.  
  7. Remove the cruise control servo from the vehicle.
  8.  
  9. Remove the cylinder head cover from the engine.
  10.  
  11. Disconnect the wire harness from the transaxle.
  12.  
  13. Remove the 2 bolts, then disconnect the 2 wire harness brackets.
  14.  
  15. Remove the 2 bolts and the ground cables from the transaxle.
  16.  
  17. Disconnect the backup lamp connector.
  18.  
  19. Disconnect the vehicle speed sensor connector.
  20.  
  21. Remove the clutch actuator cylinder and the piping from the transaxle assembly.
  22.  
  23. Remove the clip and the washer, then disconnect the shift cable from the transaxle.
  24.  
  25. Remove the clip, then disconnect the shift cable from the bracket.
  26.  
  27. Remove the clip and washer, then disconnect the shift cable from the transaxle.
  28.  
  29. Remove the clip, then disconnect the shift cable from the bracket. Remove the starter assembly from the vehicle.
  30.  
  31. Install the engine support fixture.
  32.  
  33. Remove the front wheels.
  34.  
  35. Remove the left and right lower splash shields.
  36.  
  37. Remove the exhaust pipe from the vehicle.
  38.  
  39. Remove the transaxle drain plug and the oil.
  40.  
  41. Remove the left and right drive shafts.
  42.  
  43. Remove the front suspension cross-member.
  44.  
  45. Support the transaxle with a suitable jack.
  46.  
  47. Remove the 5 bolts from the left engine mount, then remove the mount from the vehicle.
  48.  
  49. Remove the 3 bolts from the left engine mount bracket, then remove the bracket from the vehicle.
  50.  
  51. Remove the 6 bolts that secure the transaxle to the engine.
  52.  
  53. Slightly lower the transaxle.
  54.  
  55. Remove the transaxle from the engine.
  56.  

To install:

  1. Align the input shaft with the clutch disc and install the transaxle to the engine.
  2.  
  3. Install the 6 bolts that secure the transaxle to the engine. Torque the -A- bolts to 47 ft. lbs. (64 Nm), the -B- bolts to 35 ft. lbs. (47 Nm) and the -C- bolts to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the left engine mounting bracket to the transaxle with the 3 bolts. Tighten to 38 ft. lbs. (52 Nm).
  6.  
  7. Install the left engine mount with the 5 bolts and nuts. Tighten the -A- bolts to 38 ft. lbs. (52 Nm) and the -B- bolts to 59 ft. lbs. (80 Nm).
  8.  
  9. Lower the jack from the transaxle.
  10.  
  11. Install the front suspension cross-member.
  12.  
  13. Install the left and right drive shafts.
  14.  
  15. Install the left and right lower splash shields.
  16.  
  17. Install the exhaust pipe in the vehicle.
  18.  
  19. Install the front wheels.
  20.  
  21. Install the drain plug with a new gasket. Tighten to 29 ft. lbs. (39 Nm).
  22.  
  23. Fill the transaxle with 2.0 qts. (1.9L) of API GL-4 or GL-5 SAE 75W-90 or equivalent.
  24.  
  25. Install the fill plug with a new gasket. Tighten to 29 ft. lbs. (39 Nm).
  26.  
  27. Remove the engine support fixture.
  28.  
  29. Install the starter assembly from the vehicle.
  30.  
  31. Connect the shift cable to the transaxle, then install the clip and the washer.
  32.  
  33. Connect the shift cable to the bracket, then install the clip.
  34.  
  35. Connect the shift cable to the transaxle, then install the clip and the washer.
  36.  
  37. Connect the shift cable to the bracket, then install the clip.
  38.  
  39. Install the clutch actuator cylinder and the piping.
  40.  
  41. Connect the backup lamp connector.
  42.  
  43. Connect the vehicle speed sensor connector.
  44.  
  45. Connect the wire harness to the transaxle.
  46.  
  47. Connect the 2 wire harness brackets, then install the 2 bolts.
  48.  
  49. Install the 2 bolts and the ground cables to the transaxle.
  50.  
  51. Install the cruise control servo in the vehicle.
  52.  
  53. Install the battery tray and the 4 bolts.
    CAUTION
    Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

  54.  
  55. Install the battery.
  56.  
  57. Install the air cleaner case assembly.
  58.  
  59. Install the cylinder head cover in the engine.
  60.  

 
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