1996 TOYOTA TERCEL Service Repair Manual

SA118-03
N00187
SST
N00188
Washer SA-16
- SUSPENSION AND AXLEFRONT WHEEL HUB BOLT
832 Author
: Date
:
1996 TERCEL (RM440U)
FRONT WHEEL HUB BOLT
REPLACEMENT
1. REMOVE FRONT WHEEL
2. REMOVE BRAKE CALIPER AND DISC
(See page SA-10)
3. REMOVE HUB BOLT
Using SST, remove the hub bolt.
SST 09628-1001 1
4. INSTALL HUB BOLT
Install washer and nut to the hub bolt, as shown in the illustra-
tion, and install the hub bolt with torquing the nut.
5. INSTALL DISC AND BRAKE CALIPER
(See page SA-10)
Torque: 88 N´m (900 kgf´cm, 65 ft´lbf)
6. INSTALL FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)

SA127-03
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA-17
833 Author
: Date
:
1996 TERCEL (RM440U)
FRONT DRIVE SHAFT
COMPONENTS

SA128-02
FA1535
SST
F03986
SA-18
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
REMOVAL
NOTICE:

The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed. Therefore, if it is
absolutely necessary to place the vehicle weight on
the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)

w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the sensor rotor
serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. M/T:
REMOVE LH ENGINE UNDER COVER
3. DRAIN TRANSAXLE OIL (M/T) OR ATF (A/T)
4. w/ ABS:
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
5. REMOVE DRIVE SHAFT LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) While applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
6. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE (See page SA-10)
7. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See page SA-10)
8. DISCONNECT DRIVE SHAFT FROM AXLE HUB
NOTICE:
Be careful not to damage the drive shaft boot and inner oil
seal.

Z18939
LH Drive Shaft:
M/T A/T
Z18938
RH Drive Shaft:
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA-19
1996 TERCEL (RM440U)
9. LH drive shaft:
REMOVE DRIVE SHAFT
(a) M/T:
Using a hammer, remove the drive shaft.
(b) A/T:
Using a hammer and hub nut wrench or an equivalent, re-
move the drive shaft.
10. RH drive shaft:
REMOVE DRIVE SHAFT
Using a brass bar and hammer, remove the drive shaft.
11. REMOVE SNAP RING
Using a screwdriver, remove the snap ring from the inboard joint
shaft.

SA129-06
N00191
R11817
Matchmarks
N00194
Matchmarks
R09716
SST SA-20
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no play in the outboard joint.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no remarkable play in the radial
direction of the inboard joint.
2. REMOVE INBOARD JOINT TULIP
(a) Using a screwdriver, remove the 2 boot clamps.
(b) Place matchmarks on the inboard joint tulip and tripod.
(c) Remove the inboard joint tulip from the drive shaft.
3. REMOVE TRIPOD
(a) Using a snap ring expander, remove the snap ring.
(b) Place matchmarks on the shaft and tripod.
(c) Using a brass bar and hammer, remove the tripod joint
from the drive shaft.
4. REMOVE INBOARD JOINT BOOT AND 2 BOOT
CLAMPS
5. RH DRIVE SHAFT:
REMOVE DYNAMIC DAMPER
(a) Using a screwdriver, remove the damper clamp.
(b) Remove the damper from the drive shaft.
6. REMOVE OUTBOARD JOINT BOOT
(a) Using a screwdriver, remove the 2 boot clamps.
(b) Remove the boot and 2 boot clamp from the outboard
joint.
NOTICE:
Do not disassemble the outboard joint.
7. REMOVE DUST COVER
Using SST and a press, remove the dust cover from the inboard
joint tulip.
SST 09950-00020
8. w/o ABS:
REMOVE NO.2 DUST DEFLECTOR
(a) Mount the outboard joint in a soft jaw vise.
(b) Using a screwdriver, remove the No.2 dust deflector.

R11822
SST
SA12A-05
SA1459
R09694
Inboard Joint Boot Outboard Joint Boot
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA-21
1996 TERCEL (RM440U)
REASSEMBLY
1. w/o ABS:
INSTALL DUST DEFLECTOR NO.2
Using SST and a press, install a new dust deflector No.2.
SST 09309-36010, 09316-20011
2. INSTALL DUST COVER
Using a press, install a new dust cover to the inboard joint tulip.
3. TEMPORARILY INSTALL BOOTS, CLAMPS AND
DAMPER (RH DRIVE SHAFT)
HINT:
Before installing the boots, wrap vinyl tape around the spline of
the drive shaft to prevent damaging the boot.
(a) Temporarily install a new outboard joint boot.
(b) RH drive shaft:
Temporarily install the damper.
(c) Temporarily install a new inboard joint boot.
4. INSTALL TRIPOD
(a) Place the beveled side of the tripod axial spline toward the
outboard joint.
(b) Align the matchmarks before removal.
(c) Using a brass bar and hammer, tap in the tripod to the
drive joint shaft.
NOTICE:
Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
5. INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, pack the outboard joint and boot
with grease in the boot kit.
Grease capacity: 65 - 75 g (2.3 - 2.6 oz.)
6. INSTALL INBOARD JOINT TO FRONT DRIVE SHAFT
(a) Pack the inboard tulip and boot with grease in the boot kit.
Grease capacity: 112 - 122 g (4.0 - 4.3 oz.)
(b) Align the matchmarks as they were placed before disas-
sembly
(c) Install the inboard joint tulip to the drive shaft.
(d) Temporarily install the boot to the inboard joint shaft.

Z12938
RH
LH
R09908
SA-22
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
7. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Make sure the boot are on the shaft groove.
(b) Set the drive shaft length to the standard.
Standard length
RH785.1 ± 5.0 mm (30.909 ± 0.197 in.)
LH544.9 ± 5.0 mm (21.421 ± 0.197 in.)
(c) Place the 4 new boot clamps to the boots.
(d) Bend the band, and lock it with a screwdriver.
8. RH DRIVE SHAFT:
ASSEMBLE DYNAMIC DAMPER CLAMP
(a) Be sure the damper is on the shaft groove.
(b) Set the distance, as shown.
Distance: 361.4 ± 5.0 mm (14.335 ± 0.197 in.)
(c) Place a new damper clamp to the damper.
(d) Bend the band and lock it in the same procedure for the
boot clamp assembly.
9. INSTALL SNAP RING
Using a snap ring expander, install a new snap ring to the in-
board joint shaft.
10. CHECK DRIVE SHAFT (See page SA-20)

SA12B-02
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA-23
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-18).
HINT:
After installation, check ABS speed sensor signal and front wheel alignment (See page DI-1 11 and
SA-4).