1996 TOYOTA TERCEL Service Repair Manual

AX0S6-01
Q06599
SST AX-26
- AUTOMATIC TRANSAXLE (A242L)SPEEDOMETER DRIVEN GEAR OIL SEAL
1996 TERCEL (RM440U)
INSTALLATION
INSTALL SPEEDOMETER DRIVEN GEAR OIL SEAL
SST 09201-10000 (09201-01080)
Drive in depth: 25 mm (0.98 in.)

AX084-01
D01645
Key Interlock Solenoid
Stop Light SwitchShift Lock
Override Button
Shift Lock Control
Unit Assembly
BatteryMAIN
FLALTStopIgnition Switch
ACC
IGCIG
ECU-IG
IG
Shift Lock
Control ECUACC
Key Interlock Solenoid
KLS
+
E Stop Light
Switch
Stop
LightSTP WIRING DIAGRAM
- AUTOMATIC TRANSAXLE (A242L)SHIFT LOCK SYSTEM
AX-27
809 Author
: Date
:
1996 TERCEL (RM440U)
SHIFT LOCK SYSTEM
LOCATION

AX085-01
Z16063
ACCIG
KLS
+ESTP
Wire Harness Side
AT8748
AT8749
AX-28
- AUTOMATIC TRANSAXLE (A242L)SHIFT LOCK SYSTEM
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT SHIFT LOCK CONTROL ECU
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the ECU connector.
TerminalMeasuring ConditionVoltage (V)
ACC - EIgnition switch ACC10 - 14
IG - EIgnition switch ON10 - 14
STP - EDepressing brake pedal10 - 14
KLS+ - E
1 Ignition switch ACC and P position
2 Ignition switch ACC and except P position
3 (After approx 1 second)0
10 - 14
6 - 9
2. INSPECT KEY INTERLOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between ter-
minals.
Standard resistance: 12.5 - 16.5 W
If the resistance is not as specified, replace the solenoid.
(c) Apply battery positive voltage between terminals. Check
that the solenoid operation sound is heard.
If the operation is not as specified, replace the solenoid.

AX086-04
Q07636
RH Drive ShaftStarterAir Cleaner
Assembly
Speedometer Cable
Rear Engine Mounting Insulator
Plug for Governor
Pressure Test
Tie Rod End

Snap Ring
LH Drive Shaft

Gasket
Clamp
Nut Cap

Cotter Pin O/D Solenoid
Connector
Snap
Ring
x6
Hole Plug
Torque Converter
Clutch
Clip
Control
Cable
Plug for Line Pressure Test
Oxygen Sensor

Gasket
Front Exhaust Pipe
Compression Spring
Engine Under Cover

Non-reusable part
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
AX-29
811 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

AX087-03
Q06569
Q06548
Q06571
Q06572
AX-30
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE THROTTLE CABLE
4. REMOVE GROUND CABLES
5. REMOVE UPPER SIDE MOUNTING BOLTS
(a) Remove the 2 upper side mounting bolts.
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
(b) Remove the upper side starter bolt.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
6. INSTALL ENGINE SUPPORT FIXTURE
7. RAISE VEHICLE
8. REMOVE UNDER COVER
9. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-18)
10. DISCONNECT SPEEDOMETER CABLE
11. DISCONNECT CONTROL CABLE
(a) Remove the clip from the control cable.
(b) Disconnect the control cable from the lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
12. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
13. DISCONNECT O/D SOLENOID CONNECTOR
14. DISCONNECT OIL COOLER HOSE FROM PIPE
15. REMOVE STARTER
(a) Disconnect the cable and connector.
(b) Remove the starter with the bolt.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)

Q08079
Q08081
Q07892
Q08080A
BA
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
AX-31
1996 TERCEL (RM440U)
16. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
Torque: 44 N´m (450 kgf´cm, 32 ft´lbf)
(b) Remove the bolts and springs from the exhaust manifold
and front exhaust pipe.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the clamp.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(d) Remove the front exhaust pipe and gaskets.
HINT:
Replace the used gaskets with new ones.
17. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
(a) Remove the converter cover.
(b) Turn the crankshaft to gain access and remove the 6 bolts
with holding the crankshaft pulley set bolt a wrench.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
18. SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
19. DISCONNECT LH ENGINE MOUNTING BRACKET
Remove the 2 mounting bolts.
Torque: 49 N´m (490 kgf´cm, 36 ft´lbf)
20. REMOVE ENGINE REAR MOUNTING
(a) Remove the rear mounting insulator through bolt.
Torque: 65 N´m (650 kgf´cm, 48 ft´lbf)
(b) Remove the 5 bolts and rear mounting insulator.
Torque:
Bolt A: 80 N´m (800 kgf´cm, 59 in´lbf)
Bolt B: 92 N´m (920 kgf´cm, 69 ft´lbf)

Q06573
C
AB AX-32
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
1996 TERCEL (RM440U)
21. REMOVE TRANSAXLE MOUNTING BOLT
Torque:
Bolt A: 7.4 N´m (75 kgf´cm, 65 in´lbf)
Bolt B: 64 N´m (650 kgf´cm, 47 ft´lbf)
Bolt C: 46 N´m (470 kgf´cm, 34 ft´lbf)

AX088-04
AT0943
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
AX-33
1996 TERCEL (RM440U)
INSTALLATION
1. TORQUE CONVERTER CLUTCH
Using calipers and a straight edge, measure the distance from
the installed surface to the front surface of the transaxle hous-
ing.
Correct distance: More than 13.0 mm (0.512 in.)
2. TRANSAXLE INSTALLATION
Installation is in the reverse order of removal.
HINT:

After installation, adjust the shift cable and park/neutral
position switch (See page AX-2).

Fill ATF and check fluid level (See page AX-2).

Test drive the vehicle.