1996 TOYOTA TERCEL Service Repair Manual

SA11H-04
R11688
Z14904
SA-32
- SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. DISCONNECT LOWER SUSPENSION ARM FROM
LOWER BALL JOINT
Remove the 2 nuts and bolt.
Torque: 80 N´m (820 kgf´cm, 59 ft´lbf)
3. REMOVE LOWER SUSPENSION ARM
Remove the 3 bolts, lower suspension arm.
Torque:
A: 142 N´m (1,450 kgf´cm, 105 ft´lbf)
B: 74 N´m (750 kgf´cm, 55 ft´lbf)
HINT:
After stabilizing the suspension, torque the bolts.

SA11I-02
- SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
SA-33
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-32).
HINT:
After installation, check front wheel alignment (See page SA-4).

SA11J-05
SA-34
- SUSPENSION AND AXLEFRONT LOWER BALL JOINT
850 Author
: Date
:
1996 TERCEL (RM440U)
FRONT LOWER BALL JOINT
COMPONENTS

SA11K-01
SA3121
SST
- SUSPENSION AND AXLEFRONT LOWER BALL JOINT
SA-35
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE STEERING KNUCKLE WITH AXLE HUB
(See page SA-10)
2. REMOVE LOWER BALL JOINT
(a) Remove the clip and nut.
Torque: 98 N´m (1,000 kgf´cm, 72 ft´lbf)
(b) Using SST, remove the lower ball joint.
SST 09628-6201 1

SA11L-05
N00208
SA-36
- SUSPENSION AND AXLEFRONT LOWER BALL JOINT
1996 TERCEL (RM440U)
INSPECTION
INSPECT LOWER BALL JOINT FOR ROTATION CONDI-
TION
(a) As shown flip the ball joint stud back and forth 5 times, be-
fore installing the nut.
(b) Using a torque wrench, turn the nut continuously one turn
per 2 - 4 seconds and take the torque reading on the 5th
turn.
Turning torque:
0.78 - 2.45 N´m (8 - 25 kgf´cm, 7.0 - 22.0 in.´lbf)

BR0R8-01
- BRAKEBRAKE SYSTEM
BR-1
875 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE SYSTEM
PRECAUTION

Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts having the same part number
or equivalent.

It is very important to keep parts and the area clean when repairing the brake system.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.

BR0R9-06
BR-2
- BRAKETROUBLESHOOTING
876 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Lower pedal or spongy pedal
1. Brake system (Fluid leaks)
2. Brake system (Air in)
3. Piston seals (Worn or damaged)
4. Rear brake shoe clearance (Out of adjustment)
5. Master cylinder (Faulty)
6. Booster push rod (Out of adjustment)DI-145
BR-4
BR-23
BR-33
BR-9
BR-18
Brake drag
1. Brake pedal freeplay (Minimal)
2. Parking brake lever travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Rear brake shoe clearance (Out of adjustment)
5. Pad or lining (Cracked or distorted)
6. Piston (Stuck)
7. Piston (Frozen)
8. Anchor or return spring (Faulty)
9. Booster push rod (Out of adjustment)
10. Booster system (Vacuum leaks)
11. Master cylinder (Faulty)BR-6
BR-8
-
BR-33
BR-20
BR-29
BR-23
BR-23
BR-29
BR-16
BR-16
BR-9
Brake pull
1. Piston (Stuck)
2. Pad or lining (Oily)
3. Piston (Frozen)
4. Disc (Scored)
5. Pad or lining (Cracked or distorted)BR-23
BR-20
BR-29
BR-23
BR-23
BR-20
BR-29
Hard pedal but brake inefficient
1. Brake system (Fluid leaks)
2. Brake system (Air in)
3. Pad or lining (Worn)
4. Pad or lining (Cracked or distorted)
5. Rear brake shoe clearance (Out of adjustment)
6. Pad or lining (Oily)
7. Pad or lining (Glazed)
8. Disc (Scored)
9. Booster push rod (Out of adjustment)
10. Booster system (Vacuum leaks)DI-145
BR-4
BR-20
BR-29
BR-20
BR-29
BR-33
BR-20
BR-29
BR-20
BR-29
BR-23
BR-16
BR-9

- BRAKETROUBLESHOOTING
BR-3
877 Author
: Date
:
1996 TERCEL (RM440U)Symptom
Suspect AreaSee page
Noise from brake
1. Pad or lining (Cracked or distorted)
2. Installation bolt (Loosen)
3. Disc (Scored)
4. Pad support plate (Loosen)
5. Sliding pin (Worn)
6. Pad or lining (Dirty)
7. Pad or lining (Glazed)
8. Anchor or return spring (Faulty)
9. Anti-squeal shim (Damage)
10. Hold-down spring (Damage)BR-20
BR-29
BR-23
BR-23
BR-23
BR-23
BR-20
BR-29
BR-23
BR-29
BR-29
BR-20
BR-29