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Title: ABNORMAL NOISE FROM DL002-07 Technical Service REAR ... Flipbook PDF
ABNORMAL NOISE FROM REAR DIFFERENTIAL – DL002-07 August 23, 2007 Page 6 of 7 4. Remove the rear differential carrier ass
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Technical Service BULLETIN August 23, 2007
Introduction
Applicable Vehicles
ABNORMAL NOISE FROM REAR DIFFERENTIAL Models:
’03 – ’06 Matrix (AWD/4WD)
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.
S 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
PREVIOUS PART NUMBER
CURRENT PART NUMBER
PART NAME
QTY
41330–12020
41330–12040
Coupling Assembly, Transmission
1
90363–65002
90363–65004
Bearing, Radial Ball, No.1
1
90363–95003
90363–95007
Bearing, Radial Ball, No.2
1
41252–33010
Same
Rear Differential Dust Deflector
1
90310–54001
Same
Seal, Oil Diaphragm
1
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
DL7001
R & R Transmission Coupling & Bearings
7.3
41330–12020
91
13
Applicable Warranty*: This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint.
Toyota Supports ASE Certification
Page 1 of 7
DRIVELINE & DIFFERENTIAL
DL002-07
Title:
ABNORMAL NOISE FROM REAR DIFFERENTIAL – DL002-07 Required Tools & Equipment
SPECIAL SERVICE TOOLS (SSTs)
Replacer Set 1*
August 23, 2007 PART NUMBER
QTY
DRW**
09950–60010–02
1
24
09950–70010–01
1
25
00002–00909–01
1
25
09550–55011–01 (or Equivalent)
1
–
09223–15030 (or Equivalent)
1
3
Four (4) components from this kit/set are required: COMPONENT(S) OF KIT/SET
S Replacer 46 (P/N 09951–00460–01) S Replacer 53 (P/N 09951–00530–01) S Adapter (P/N 09952–06010–01)
Handle Set* COMPONENT(S) OF KIT/SET
One (1) component from this kit/set is required: S Handle Assembly 150 – 6.25 inch (P/N 09951–07150–01)
All Trac Tool Set*
COMPONENT(S) OF KIT/SET
One (1) component from this kit/set is required: S Bearing Replacer (P/N 09502–12010–01)
Differential Replacer Set
COMPONENT(S) OF KIT/SET
One (1) component from this kit/set is required: S Replacer B (P/N 09550–05061)
Crankshaft Rear Oil Seal Replacer* NOTE: Use with 09620–30010–02 * Essential SSTs. ** Drawer number in SST Storage System.
Page 2 of 7
ABNORMAL NOISE FROM REAR DIFFERENTIAL – DL002-07 Required Tools & Equipment (Continued)
August 23, 2007
SPECIAL SERVICE TOOLS (SSTs)
Rack & Pinion Steering Tool Set
COMPONENT(S) OF KIT/SET
PART NUMBER
QTY
DRW**
09630–24014–01 (or Equivalent)
1
–
09518–36020 (or Equivalent)
1
–
One (1) component from this kit/set is required: S Handle (P/N 09620–30010–02)
Rear Axle Hub Oil Seal Replacer
* Essential SSTs. ** Drawer number in SST Storage System.
NOTE: Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
REQUIRED EQUIPMENT
ChassisEARt (or equivalent)
SUPPLIER
PART NUMBER
QTY
ADE
JSPSM06606 (JS Products)
1
NOTE: S A mechanic’s stethoscope or similar tool may be used in place of ChassisEARt. S ChassisEARt may be ordered by calling Toyota Approved Dealer Equipment (ADE) at 1–800–368–6787.
TOOLS & MATERIAL
Mechanics Stethoscope (or equivalent)***
QUANTITY
1
*** Use this tool if ChassisEARt is unavailable. (See Required Equipment above.)
Page 3 of 7
ABNORMAL NOISE FROM REAR DIFFERENTIAL – DL002-07 Repair Procedure
August 23, 2007
1. Test drive the vehicle and confirm the customer complaint. 2. Isolate the source of the noise using ChassisEARt, mechanic’s stethoscope, or similar tool. Is the noise coming from the area indicated in the illustration below? Rear Suspension Member With Rear Differential & Suspension 137 (1400, 101)
167 (1700, 123)
Differential Support 167 (1700, 123)
Differential Carrier Assembly Rear
No. 1 Rear Differential Support
118 (1200, 87)
103 (1050, 76) NSm (kgfScm, ftSlbf) : Specified Torque
S If Yes – This TSB applies. Go to step 3. S If No – STOP – This TSB does NOT apply. Continue diagnosis using the Repair Manual. Page 4 of 7
ABNORMAL NOISE FROM REAR DIFFERENTIAL – DL002-07 Repair Procedure (Continued)
August 23, 2007
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 below for the circled parts which are required to be replaced.) Transmission Coupling Radial Ball Bearing No. 1 Transmission Coupling Radial Ball Bearing No. 2
Transmission Coupling Conical Spring Washer
Rear Differential Carrier Cover Transmission Coupling Spacer Transmission Coupling Assembly
X4
98 (1000, 72) Rear Differential Dust Deflector
Rear Differential Filler Plug (Inspection Plug)
20 (200, 14)
Gasket
Oil Diaphragm Seal
4.9 (50, 43 in.Slbf)
X2
42 (430, 31)
X10
Gasket
Non–reusable Part
Gasket
39 (398, 29) Rear Differential Drain Plug
MP Grease 39 (398, 29) Hypoid Gear Oil NSm (kgfScm, ftSlbf) : Specified Torque
Rear Differential Drain Plug (Filler Plug)
Page 5 of 7
ABNORMAL NOISE FROM REAR DIFFERENTIAL – DL002-07 Repair Procedure (Continued)
August 23, 2007
4. Remove the rear differential carrier assembly from the vehicle. Refer to the Technical Information System (TIS): S 2003 – 2005 model year Matrix Repair Manual, Drivetrain – Axle/Differential – “Rear Differential Carrier Assy Rear (for 4WD): Overhaul”. S 2006 model year Matrix Repair Manual, Drivetrain – Axle/Differential – “Differential: Rear Differential Carrier Assembly (for 4WD): Removal”. 5. Replace the transmission coupling assembly (viscous coupling), both radial ball bearing assemblies, and rear differential dust deflector using the procedures below. 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. S SST P/N 09502–12010 S SST P/N 09550–55011 (09550–05061) S SST P/N 09950–70010 (09951–07150)
Page 6 of 7
SST
ABNORMAL NOISE FROM REAR DIFFERENTIAL – DL002-07 Repair Procedure (Continued)
August 23, 2007
B. Using the SSTs and a press, install the transmission coupling radial ball bearing No. 2. S SST P/N 09223–15030 S SST P/N 09950–70010
SST
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
SST
S SST P/N 09518–36020 S SST P/N 09950–70010 (09951–07150) E. Install the transmission coupling spacer. F. Install the transmission coupling conical spring washer.
Block
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 NEW oil diaphragm seal. H. Install the rear differential carrier cover with the 4 bolts to the differential carrier. Torque: 20 NSm (200 kgfScm, 14 ftSlbf)
7. Install the rear differential carrier assembly in the vehicle. Refer to TIS: S 2003 – 2005 model year Matrix Repair Manual, Drivetrain – Axle/Differential – “Rear Differential Carrier Assy Rear (for 4WD): Overhaul”. S 2006 model year Matrix Repair Manual, Drivetrain – Axle/Differential – “Differential: Rear Differential Carrier Assembly (for 4WD): Installation”. 8. Test drive the vehicle and confirm the vehicle is repaired.
Page 7 of 7