1996 TOYOTA TERCEL Service Repair Manual

AT0952
SST
AX0S7-01
AT0953
AT3306
Hold
TurnLock
Free
AT2821
AT2820
AX-34
- AUTOMATIC TRANSAXLE (A242L)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
816 Author
: Date
:
1996 TERCEL (RM440U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE-WAY CLUTCH
(a) Install SST in the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
(c) With the torque converter clutch held upright, inspect the
clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch. Replace
the converter clutch if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, and measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification, replace the drive
plate.
Torque: 88 N´m (900 kgf´cm, 65 ft´lbf)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correct by reori-
enting the installation of the converter.
HINT:
Mark the position of the converter clutch to ensure the correst
installation.

SA10Z-04
- SUSPENSION AND AXLETROUBLESHOOTING
SA-1
817 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table to help you find the cause of the problem. The numbers indicate the priority of the likely case
of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Wander/pulls
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering linkage (Loosen or worn)
4. Hub bearings (Worn)
5. Steering gear (Out of adjustment or broken)
6. Suspension parts (Worn)SA-2
SA-4
SA-8
-
SA-10
SA-39
SR-34
SR-46
-
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)-
SA-24
SA-44
SA-24
SA-44
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Rear axle beam)
3. Shock absorber (Worn)SA-2
SA-54
SA-24
SA-44
Front wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheels (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Ball joint (Worn)
6. Hub bearing (Worn)
7. Steering linkage (Loosen or worn)
8. Steering gear (Out of adjustment or broken)SA-2
SA-2
SA-24
SA-4
SA-34
SA-10
-
SR-34
SR-46
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Suspension parts (Worn)
4. Shock absorber (Worn)SA-2
SA-4
SA-8
-
SA-24
SA-44

SA110-03
R03031
R15157
Front
R07928
SA-2
- SUSPENSION AND AXLETIRE AND WHEEL
818 Author
: Date
:
1996 TERCEL (RM440U)
TIRE AND WHEEL
INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and for the proper inflation pres-
sure.
Cold inflation pressure
Tire sizeFront
kPa (kgf/cm2, psi)
Rear
kPa (kgf/cm2, psi)
155SR13 AS240 (2.4, 34)225 (2.25, 32)
(b) Check the tire runout.
Tire runout: 1.4 mm (0.055 in.) or less
2. ROTATING TIRES
HINT:
See the illustration for where to rotate each tire.
3. INSPECT WHEEL BALANCE
(a) Check and adjust the Off-the-car balance.
(b) If necessary, check and adjust the On-the-car balance.
Unbalance after adjustment: 8.0 g (0.018 lb) or less

R11682
- SUSPENSION AND AXLETIRE AND WHEEL
SA-3
819 Author
: Date
:
1996 TERCEL (RM440U)
4. CHECK WHEEL BEARING LOOSENESS
(a) Check the backlash in bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
(b) Check the axle hub deviation.
Maximum: 0.05 mm (0.0020 in.)
5. CHECK FRONT SUSPENSION FOR LOOSENESS
6. CHECK STEERING LINKAGE FOR LOOSENESS
7. CHECK BALL JOINT FOR LOOSENESS
8. CHECK SHOCK ABSORBER WORKS PROPERLY

Check for oil leaks

Check mounting bushings for wear

Bounce front and rear of the vehicle

R11681R11753F02280
Front
RearSA23E-01
Z03382
SA3213
AB
C D
Front SA-4
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
820 Author
: Date
:
1996 TERCEL (RM440U)
FRONT WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT
Tire sizeFrontRear
155SR13187.9 mm (7.40 in.)253.2 mm (9.97 in.)
Front measuring point:
Measure from the ground to the center of the lower suspension
arm front mounting bolt.
Rear measuring point:
Measure from the ground to the center of the axle beam mount-
ing bolt.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specification.
If the vehicle height is not the specification, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER-CASTER-KINGPIN GAUGE OR
ONTO WHEEL ALIGNMENT TESTER
Follow the specific instruction of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
Camber
Left-right error-0°20' ± 45'
45' (0.75°) or less
Caster
Left-right error1°20' ± 45
45' (0.75°) or less
Steering axis inclination
Left-right error12°10' ± 45'
45' (0.75°) or less
HINT:
If the caster and steering axis inclination are not within the spec-
ification, after the camber has been correctly adjusted, recheck
the suspension parts for damaged and/or worn out parts.
4. INSPECT TOE-IN
Toe-in
(total)A + B: 0.1° ± 0.2°
C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
If the toe-in is not within the specification, adjust by the tie rod
end.

F03984
R15511



- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA-5
821 Author
: Date
:
1996 TERCEL (RM440U)
5. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheels.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
(c) Coat the threads of the nuts with engine oil.
(d) Temporarily install the 2 nuts.
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
Adjusting value: 0°06' - 0°30'
(f) Tighten the nuts.
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
(g) Install the front wheels.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
Camber
Left-right error-0°20' ± 45'
45' (0.75°) or less
HINT:

Try to adjust the camber to the center value.

Adjusting value for the set bolts is 6' - 30' (0.1° - 0.5°).

F01195
Bolt
Adjusting
ValueSet Bolt
15'
30'Adjusting Bolt90105-15001 90105-15004 90105-15005 90105-15006
45'
1°00'
1°15'
1°30'121212121 Dot 2 Dots 3 Dots
W00533
W00533
SA-6
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
822 Author
: Date
:
1996 TERCEL (RM440U)
If the camber is not within the specification, using the table be-
low, estimate of how much additional camber adjustment will be
required, and select the camber adjusting bolt.
(i) Follow the above mentioned steps again. Between step
(b) and (c), exchange 1 or 2 selected bolts.
HINT:
When exchanging the 2 bolts, exchange 1 bolt for each time.
6. ADJUST TOE-IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right rack ends an equal amount to adjust
the toe-in.
Toe-in
(total)A + B: 0.1° ± 0.2°
C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
HINT:

Try to adjust the toe-in to the center value.

Make sure that the lengths of the left and right rack ends
are the same.
Tie rod end length difference: 1.5 mm (0.059 in.) or
less
(d) Torque the tie rod end lock nuts.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
(e) Place the boots on the seat and install the clamps to them.
HINT:
Make sure that the boots are not twisted.

SA0028
A: Inside
B: Outside AB
Front BA
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA-7
823 Author
: Date
:
1996 TERCEL (RM440U)
7. INSPECT WHEEL ANGLE
Turn the steering wheel fully, and measure the turning angle.
Inside wheel35°55' ± 2°
Reference: Outside wheel32°10'
If the wheel angles differ from the standard specifications, in-
spect the toe-in.