1996 TOYOTA TERCEL clutch

MX07O-02
D02999
Engine Side
Z08629
N00067
N00068
- MANUAL TRANSAXLEINPUT SHAFT
MX-25
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply gear oil to the needle roller bearings.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Using a press, install the 3rd gear and No.2 hub sleeve
assembly.
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
02.30 (0.0906)32.48 (0.0976)
12.36 (0.0929)42.54 (0.1000)
22.42 (0.0953)52.60 (0.1024)
(b) Using a screwdriver and hammer, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MX-21)

MX07P-01
Q06509
Needle Roller Bearing
1st Gear
No.1 Hub Sleeve
Shifting Key
No.1 Clutch Hub
Synchronizer RingOutput Shaft Assembly Ball
Thrust Washer
Synchronizer Ring
Needle Roller Bearing
2nd GearShifting Key Spring
Snap Ring
3rd Driven Gear
Output Gear Spacer
4th Driven Gear
Rear Ball Bearing
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-27
739 Author
: Date
:
1996 TERCEL (RM440U)
OUTPUT SHAFT
COMPONENTS

MT0063
SST
N00076
CM0142
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-29
1996 TERCEL (RM440U)
(b) Using SST and a press, remove the 3rd driven gear and
2nd gear.
SST 09950-00020
(c) Remove the needle roller bearing and synchronizer ring.
5. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, remove the snap ring.
6. REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR,
SYNCHRONIZER RING, NEEDLE ROLLER BEARING,
THRUST WASHER AND BALL
(a) Using a press, remove the No.1 hub sleeve assembly, 1st
gear and synchronizer ring.
(b) Remove the needle roller bearing, thrust washer and ball.
7. REMOVE NO.1 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO.1 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs
from the No.1 clutch hub.

MX07S-03
CM0009
Engine Side
N00077
N00078
N00079
MX-32
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the No.1 clutch hub and shifting keys to the No.1
hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL BALL, THRUST WASHER, 1ST GEAR,
NEEDLE ROLLER BEARING, SYNCHRONIZER RING
AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT
SHAFT
(a) Install the ball to the shaft.
(b) Fit the thrust washer groove securely over the locking ball
when installing the thrust on the shaft.
(c) Apply gear oil to the needle roller bearing.
(d) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(e) Using a press, install the 1st gear and No.1 hub sleeve.

AX08C-03
D09117
No.2 One-way
Clutch (F
2)
1st and Reverse
Brake (B
3) Rear Planetary
Ring Gear
Counter Drive Gear2nd Coast
Brake (B
1)
Direct
Intermidiate ShaftRear Planetary
Carrier
No.1 One-way
Clutch (F
1)Clutch (C
2) 2nd
Brake (B2)
Forward
Clutch (C
1)
Front and Rear
Planetary
Sun GearFront Planetary CarrierInput Shaft
Gear position Shift lever
Position
Parking
Reverse
2nd
2nd* Neutral
3rd 1st
2nd 1st
1st D
2 R
L P
NB
1B3F1C2C1

F
2


































*: Down-shift in L position, 2nd gear only, no up-shift.
....Operating
B
2
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-1
753 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE SYSTEM (A132L)
OPERATION

AX0RI-02
(b) Check the idle speed.
(e) Check the shift linkage. (d) Check the throttle cable mark.
(f) Check the park/neutral position switch.
Check the engine and the torque converter clutch. (c) Check the fluid level and fluid condition.
STALL TEST
TIME LAG TEST PRELIMINARY CHECK
ROAD TEST HYDRAULIC TEST
MATRIX CHART (a) Check the tire inflation.
Measure the line pressure and make a basic check of fluid circuit.
Check if trouble lies within automatic transaxle. If noise or vibration occurs, the possible cause could
be with the compressor, engine, drive shaft and tires, etc. Check the automatic transaxle (each clutch, brake and gear) for wear.
(See page AX-10) AX-2
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
TROUBLESHOOTING
1. GENERAL INFORMATION
(a) Troubles occurring with the automatic transaxle can be caused by either the engine or the transaxle
itself. These two areas should be checked before proceeding with troubleshooting.
(b) Troubleshooting should begin with the simplest operation, working up in order of difficulty, but first de-
termine whether the trouble lies within the engine or transaxle.
(c) Proceed with the inspection as follows:

AX-6
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
(4) Keep your left foot pressing firmly on the brake pedal.
(5) Start the engine.
(6) Shift it into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed: 2,300 ± 200 rpm
(7) Do the same test in the R position.
Stall speed: 2,300 ± 200 rpm
EVALUATION
ProblemPossible cause
(a) Stall speed low in D and R positions. Engine output may be insufficient
 Stator one-way clutch is not operating properly
(b) Stall speed high in D position.
 Line pressure too low
 Forward clutch slipping
 No.2 one-way clutch not operating properly
(c) Stall speed high in R position.
 Line pressure too low
 Direct clutch slipping
 1st and reverse brake slipping
(d) Stall speed high in D and R positions. Line pressure too low
 Improper fluid level
4. MEASURE TIME LAG TEST
When the shift lever is shifted while the engine is idling, there will be a certain time elapse or lag before the
shock can be felt. This is used for checking the condition of the forward clutch, direct clutch and 1st and re-
verse brake.
NOTICE:
Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176°F).
Make sure to allow 1 minute interval tests.
Make 3 measurements and take the average value.
(1) Fully apply the parking brake.
(2) Start the engine and check the idle speed.
Idling speed: 750 ± 50 rpm (In N position and A/C OFF)
(3) Shift the shift lever from the N to D position. Using a stop watch, measure the time it takes from
shifting the lever to the shock is felt.
Time lag: Less than 1.2 seconds
(4) In the same way, measure the time lag for N " R.
Time lag: Less than 1.5 seconds
EVALUATION (If N " D time lag are longer than than specified):
ProblemPossible cause
NDti l i l
 Line pressure too low
 Forward clutch worn
N " D time lag is longer Forward clutch worn
 Direct clutch worn
 1st and reverse brake worn

- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-7
1996 TERCEL (RM440U)
5. HYDRAULIC TEST
(a) Measure the line pressure.
(1) Warm up the transaxle fluid.
(2) Remove the transaxle case test plug and mount SST (See page AX-25).
SST 09992-00094 (09992-00150, 09992-00270)
NOTICE:
Do the test at normal operating fluid temperature 50 - 80°C (122 - 176 °F).
(3) Fully apply the parking brake and check the 4 wheels.
(4) Start the engine and check the idle speed.
(5) Shift into the D position,step down strongly on the brake pedal with your left foot and while manip-
ulating the accelerator pedal with the right foot, measure the line pressure at the engine speeds
specified in the toble.
(6) In the same manner, do the test in the R position.
Specified line pressure:
D positionIdling
Stall363 - 422 kPa (3.7 - 4.3 kgf/cm2, 53 - 61 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
R position Idling
Stall530 - 706 kPa (5.4 - 7.2 kgf/cm2, 77 - 102 psi)
1,412 - 1,647 kPa (14.4 - 16.8 kgf/cm2, 205 - 239 psi)
(7) If the measured pressures are not up to specified values, recheck the throttle cable adjustment
and retest it (see step 2).
EVALUATION
ProblemPossible cause
If the measured values at all positions are higher.
 Throttle cable out of adjustment
 Throttle valve defective
 Regulator valve defective
If the measured values at all positions are lower.
 Throttle cable out of adjustment
 Throttle valve defective
 Regulator valve defective
 Oil pump defective
If pressure is low in the D position only. D position circuit fluid leakage
 Forward clutch defective
If pressure is low in the R position only.
 R position circuit fluid leakage
 Direct clutch defective
 1st and reverse brake defective
(b) Measure the governor pressure.
(1) Warm up the transaxle fluid.
(2) Remove the transaxle case test plug and mount SST (See page AX-25).
SST 09992-00094 (09992-00230, 09992-00270)
NOTICE:
Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176 °F).
(3) Check the parking brake to see that it is not applied.
(4) Start the engine.
(5) Shift into the D position and measure the governor pressures at the speeds specified in the table.