1996 TOYOTA TERCEL e brake

AX-8
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U)
EVALUATION
ProblemPossible cause
If there is no 1 - 2 up-shift.
Governor valve is defective

1 - 2 shift valve is stuck
If there is no 2 - 3 up-shift.
1 - 2 shift valve is stuck
If there is no 3 - O/D up-shift
(throttle valve operating less than 86%).
3 - O/D shift valve is stuck

Solenoid valve or circuit defective
If the shift point is defective.

Throttle cable out of adjustment

Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, 3 - O/D shift valve etc. are
defective
(2) In the same way, check the shock and slip at 1 " 2, 2 " 3 and 3 "O/D up-shifts.
EVALUATION
ProblemPossible cause
If the shock is severe.

Line pressure is too high

Accumulator is defective

Check ball is defective
(3) Run in the 3rd gear or O/D of the D position, check the abnormal noise and vibration.
HINT:
Check for the cause of abnormal noise and vibration must be made with extreme care as they could also
be due to unbalance in the drive shaft, differential, tires and torque converter clutch, etc.
(4) While running in the 3rd gear or O/D of the D position, check that the possible kick-down vehicle
speed limits for the 3 " 1, 3 " 2 and O/D "2 kick-down conform to those indicated in the auto-
matic shift schedule (See page SS-30).
EVALUATION
ProblemPossible cause
If the possible kick-down vehicle speed limit is defective.

Throttle cable out of adjustment

Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, 3 - O/D shift valve etc. are
defective
(5) Check the abnormal shock and slip at kick-down.
(6) While running at about 60 km/h (37 mph) in the O/D of the D position, release your foot from the
accelerator pedal and shift into the L position. Then check if the 2 "1 down-shift point conforms
to that indicated in the automatic shift schedule (See page SS-30).
(b) Inspect the lock-up mechanism.
(1) Drive in the D position at a steady speed (Lock-up ON) of about 70 km/h (43 mph).
(2) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly.
If there is a big jump in engine RPM, there is no lock-up.
(c) 2 position test.
(1) While running in the 2nd gear of the 2 position, release the accelerator pedal and check the en-
gine braking effect.
EVALUATION
ProblemPossible cause
If these is no engine braking effect.
2nd coast brake is defective.
(2) Check the abnormal noise during acceleration and deceleration.
(3) Check the shock during up-shift and down-shift.
(d) L position test.
(1) While running in the L position, check that there is no up-shift to 2nd gear.
(2) While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.

- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-9
1996 TERCEL (RM440U)
EVALUATION
ProblemPossible cause
If these is no engine braking effect.
1st & reverse brake is defective.
(3) Check for abnormal noise during acceleration and deceleration.
(e) R position test.
Shift into the R position and, while running at full throttle, check for slipping.
(f) P position test.
Stop the vehicle on a gradient (more than 5°) and, after shifting into the P position, release the parking
brake. Then check that the parking lock pawl prevents the vehicle from moving.

AX07X-05
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-13
1996 TERCEL (RM440U)
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.
ON-VEHICLE:
SymptomSuspect AreaSee page
Does not move in any forward position
4. Forward clutch (C1)
5. No.2 one-way clutch (F
2)
6. 1st & reverse brake (B
3)
7. 2nd brake (B
2)
8. 2nd coast brake (B
1)
9. Direct clutch (C
2)












Does not move in reverse position
1. 2nd coast brake (B1)
2. Front planetary gear
3. Rear planetary gear
4. 1 - 2 shift valve
5. 2 - 3 shift valve
6. Direct clutch (C
2)
7. U/D clutch (C
3)
8. 1st and reverse brake (B
3)
















Does not move in any forward position or reverse position
1. Parking lock pawl
2. Manual valve
3. U/D one-way clutch (F
3)
4. U/D clutch (C
3)
5. U/D brake (B
0)
6. Front planetary gear
7. Rear planetary gear
8. U/D planetary gear
9. Torque converter clutch
















AX-34
No-up shift
(1st " 2nd)1. 1 - 2 shift valve
2. 2nd brake (B
2)
3. No.1 one-way clutch (F
1)






No-up shift
(2nd " 3rd)1. 2 - 3 shift valve
2. Direct clutch (C
2)




No-up shift
(3rd " O/D)1. U/D brake (B0)
2. 3 - 4 shift valve



No-down shift
(O/D " 3rd)3 - 4 shift valve

No-down shift
(3rd " 2nd)2 - 3 shift valve

No-down shift
(2nd " 1st)1. 1 - 2 shift valve
2. 2nd coast brake (B
1)




Shift point too high or too low
1. Governor valve
2. 1 - 2 shift valve
3. 2 - 3 shift valve
4. 3 - 4 shift valveAX-21






Up-shifts 3rd " O/D with O/D main switch ''OFF''Electric control systemAX-2
Harsh engagement
(N " R)1. Direct clutch (C2)
2. 1st & reverse brake (B
3)
3. Accumulator control valve






Harsh engagement
(N " D)1. Forward clutch (C1)
2. C
1 accumulator




Harsh engagement
(N " L)Low coast modulator valve

AX-14
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U) Harsh engagement
(1st " 2nd ºDº position)
1. B2 accumulator
2. 1st and reverse brake (B
3)




Harsh engagement
(1st " 2nd º2º position)2nd coast modulator valve

Harsh engagement
(1st " 2nd " 3rd)1. Accumulator control valve
2. Throttle modulator valve



Harsh engagement
(1st " 2nd " 3rd " O/D)Accumulator control valve

Harsh engagement
(2nd " 3rd)1. 2nd coast brake (B1)
2. C
2 accumulator




Harsh engagement
(3rd " O/D)
1. U/D clutch (C3)
2. U/D brake (B
4)
3. U/D planetary gear
4. B
4 accumulator








Harsh engagement
(O/D " 3rd)1. B4 accumulator
2. C
3 accumulator




Harsh engagement
(3rd " 2nd)
1. B4 accumulator
2. C
3 accumulator
3. 2nd coast modulator valve
4. B
2 accumulator
5. 1st and reverse brake










No lock-up1. Lock-up relay valve
2. Torque converter clutch

AX-34
No lock-up OFF1. Lock-up relay valve
2. Torque converter clutch

AX-34
Slip or shudder
(Forward & Reverse After warm-up)1. Torque converter clutch
2. U/D one-way clutch (F
3)
3. U/D clutch (C
3)
AX-34




Slip or shudder
(Forward & Reverse Directly after E/G start)1. Torque converter clutch
2. Pressure relief valve
3. Oil strainerAX-34


AX-16
Slip or shudder
(''R'' position)1. Direct clutch (C2)
2. U/D clutch (C
3)
3. 1st and reverse brake






Slip or shudder
(1st)1. Forward clutch (C1)
2. No.2 one-way clutch (F
2)




Slip or shudder
(2nd)1. C2 accumulator
2. 2nd brake (B
2)
3. No.1 one-way clutch (F
1)






Slip or shudder
(2nd "3rd Up-shift)Direct clutch (C2)

Slip or shudder
(3rd)Direct clutch (C2)

Slip or shudder
(O/D)U/D brake (B4)

No engine braking
(1st "3rd)U/D clutch (C3)

No engine braking
(1st)1. Low coast modulator valve
2. 1st and reverse brake



No engine braking
(2nd)1. 2nd coast brake (B1)
2. 2nd coast modulator valve

- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-15
1996 TERCEL (RM440U)
OFF-VEHICLE:
SymptomSuspect AreaSee page
Large shock during lock-upTorque converter clutchAX-34
E/G stalls when starting off and stoppingTorque converter clutchAX-34
Poor acceleration
(All-positions)Torque converter clutchAX-34
Poor acceleration
(O/D)1. U/D clutch (C3)
2. U/D planetary gear



Poor acceleration
(Other than O/D)1. U/D brake (B4)
2. U/D planetary gear



Poor acceleration
(Other than 2nd)1. 2nd coast brake (B1)
2. 2nd brake (B
2)




Poor acceleration
(1st and 2nd)Direct clutch (C2)

Poor acceleration
(1st and ''R'')1st and reverse brake (B3)

Poor acceleration
(''R'')Forward clutch (C1)


: Refer to A242L Automatic Transaxle Repair Manual (Pub. No. RM431U).

AT3328
Z15031
B
B
A
C
A AA
B
OR0038
AT5616
AT2713
- AUTOMATIC TRANSAXLE (A242L)VALVE BODY ASSEMBLY
AX-17
799 Author
: Date
:
1996 TERCEL (RM440U)
6. REMOVE MANUAL DETENT SPRING
Remove the bolt and detent spring.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
HINT:
Check that the manual valve lever is in contact with the center
of the roller at the tip of the detent spring.
7. DISCONNECT SOLENOID CONNECTOR
8. REMOVE VALVE BODY
(a) Remove the 12 bolts.
Bolt length:
A: 20 mm (0.79 in.)
B: 30 mm (1.18 in.)
C: 55 mm (2.17 in.)
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(b) Disconnect the throttle cable.
NOTICE:
Be careful not to entangle the kick-down switch and sole-
noid wire.
(c) Disconnect the manual valve connecting rod.
(d) Remove the valve body.
9. REMOVE 2ND BRAKE APPLY GASKET
HINT:
Replace the used gasket with a new one.

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.

SA114-03
R11682
F03986
F03987
SA-10
- SUSPENSION AND AXLEFRONT AXLE HUB
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. w/ ABS
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
3. REMOVE FRONT BRAKE CALIPER AND DISC
(a) Remove the 2 bolts and brake caliper from the steering
knuckle.
Torque: 88 N´m (900 kgf´cm, 65 in.´lbf)
(b) Support the brake caliper securely.
(c) Remove the disc.
4. CHECK BACKLASH IN BEARING SHAFT DIRECTION
Using a dial indicator, check the backlash near the center of the
axle hub, and check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
5. CHECK AXLE HUB DEVIATION
Using a dial indicator, check the deviation at the surface of the
axle hub outside the hub bolt.
Maximum: 0.05 mm (0.0020 in.)
If the deviation exceeds the maximum, replace the axle hub.
6. REMOVE DRIVE SHAFT LOCK NUT
(a) Install the brake disc and caliper.
(b) Remove the cotter pin and lock cap.
(c) With applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
(d) Remove the brake caliper and disc.
7. LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK AB-
SORBER
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
HINT:

Do not remove the 2 bolts.

Coat the nut's thread with engine oil.