1996 TOYOTA TERCEL Service Repair Manual

R12036
SST
R15598
SSTVinyl Tape
R13864
Cutout Portion SR-38
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
7. REMOVE PINION BEARING ADJUSTING SCREW
LOCK NUT
Using SST, remove the nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
8. REMOVE PINION BEARING ADJUSTING SCREW
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the steering pinion.
(b) Using SST, remove the screw.
SST 09612-24014 (09616-10020)
9. REMOVE STEERING PINION WITH BEARING
Fully pull the steering rack from the steering pinion side of the
rack housing and align the rack cutout portion with the pinion.
NOTICE:
Be careful not to damage the serrations.
10. REMOVE STEERING RACK
NOTICE:
To avoid damaging the bushing, remove the rack from the
steering pinion housing side of the rack housing without
revolving it.

SR0KU-02
R13855
Dial Indicator
R14424
SST
F05533
SST
N00343
R15525
SST SST
Bearing
- STEERINGMANUAL STEERING GEAR
SR-39
1996 TERCEL (RM440U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT STEERING RACK
(a) Using a dial indicator, check the rack for runout and for
teeth wear and damage.
Maximum runout: 0.30 mm (0.0118 in.)
(b) Check the back surface for wear and damage.
2. IF NECESSARY, REPLACE BEARING
(a) Using SST, remove the bearing.
SST 09950-40010 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04050,
09957-04010, 09958-04010)
NOTICE:
Be careful not to damage the pinion.
(b) Coat a new bearing with molybdenum disulfide lithium
base grease.
(c) Using SST, press in the bearing.
SST 09612-24014 (09612-10061)
NOTICE:
Make sure to install the bearing facing the correct direc-
tion.
3. IF NECESSARY, REPLACE BEARING
(a) Heat the rack housing to above 80°C (176°F).
(b) Using a plastic hammer, tap out the bearing from the rack
housing.
(c) Heat the rack housing to above 80°C (176°F).
(d) Coat a new bearing with molybdenum disulfide lithium
base grease.
(e) Using SST, press in the bearing.
SST 09950-60010 (09951-00340),
09950-70010 (09951-07150)

SR4254
N00345
R14426
SST
Oil Seal
W04041
SST
5 mm
Oil Seal SR-40
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
4. IF NECESSARY, REPLACE BUSHING
(a) Using a screwdriver, depress the projections on the bush-
ing to release the bushing, then remove the bushing from
the rack housing.
(b) Ensure that the hole of the rack housing is not clogged
with grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.
(c) Coat inside a new bushing with molybdenum disulfide lith-
ium base grease.
(d) Install the bushing into the rack housing, making sure to
align into the 3 holes.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, press out the oil seal from the pinion bearing
adjusting screw.
SST 09950-60010 (09951-00240),
09950-70010 (09951-07100)
(b) Coat a new oil seal lip with molybdenum disulfide lithium
base grease.
(c) Using SST, press in the oil seal with it is protruding 5 mm
(0.21 in.).
SST 09950-60010 (09951-00240),
09950-70010 (09951-07100)
NOTICE:
Make sure to install the oil seal facing the correct direction.

SR0KV-01
R13860
Steering
Pinion
Steering
Rack
Cutout Portion
R15598
SSTVinyl Tape
SR4258
SST
- STEERINGMANUAL STEERING GEAR
SR-41
1996 TERCEL (RM440U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM
BASE GREASE
(See page SR-34)
2. INSTALL STEERING RACK
Install the rack into the rack housing.
NOTICE:
To avoid damaging the bushing, install the rack from the
steering pinion side of the rack housing without revolving
it.
3. INSTALL STEERING PINION
(a) Set the steering rack notched side so that the pinion can
be positioned inside.
(b) Line up the cutout portion of the rack with the pinion.
(c) Ensure that the pinion end is securely located in the bear-
ing.
NOTICE:
Do not engage the pinion teeth with the rack teeth.
4. INSTALL PINION BEARING ADJUSTING SCREW
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the steering pinion.
(b) Apply sealant to 2 or 3 threads of the screw.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, temporarily install the screw.
SST 09612-24014 (09616-10020)
5. ADJUST PINION PRELOAD
NOTICE:
Do not engage the pinion teeth with the rack teeth.
(a) Using SST and a torque wrench, tighten the pinion bear-
ing adjusting screw until the preload matches the specifi-
cation.
SST 09612-24014 (09616-10010, 09616-10020)
Preload (turning):
0.4 N´m (3.7 kgf´cm, 3.2 in.´lbf)

R12038
SSTFulcrum Length SR-42
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
(b) Using SST and a torque wrench, loosen the screw until
the preload is within specification.
SST 09612-24014 (09616-10010, 09616-10020)
Preload (turning):
0.23 - 0.32 N´m (2.3 - 3.3 kgf´cm, 2.0 - 2.9 in.´lbf)
6. INSTALL PINION BEARING ADJUSTING SCREW
LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, stop the pinion bearing adjusting screw rotat-
ing and using another SST, torque the nut.
SST 09612-24014 (09616-10020), 09922-10010
Torque: 85 N´m (871 kgf´cm, 63 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 380 mm (14.96
in.).
(c) Recheck the pinion preload.
Preload (turning):
0.23 - 0.32 N´m (2.3 - 3.3 kgf´cm, 2.0 - 2.9 in.´lbf)
7. INSTALL RACK GUIDE, RACK GUIDE SPRING AND
RACK GUIDE SPRING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Temporarily install the cap.

R12818Hexagon Wrench12°
R15481
SST
Z14313
Hexagon WrenchSST
R15482
Hexagon
Wrench SST
Fulcrum
Length
- STEERINGMANUAL STEERING GEAR
SR-43
1996 TERCEL (RM440U)
8. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (19 mm), torque the rack guide
spring cap.
Torque: 14.7 N´m (150 kgf´cm, 10.8 ft´lbf)
(c) Using a hexagon wrench (19 mm), return the cap 12°.
(d) Using SST, turn the pinion shaft right and left 1 or 2 times.
SST 09612-24014 (09616-10010)
(e) Using a hexagon wrench (19 mm), loosen the cap until the
rack guide spring is not functioning.
(f) Using SST, a torque wrench and hexagon wrench (19
mm), tighten the cap until the preload is within specifica-
tion.
SST 09612-24014 (09616-10010)
Preload (turning):
0.6 - 1.2 N´m (6 - 12 kgf´cm, 5.2 - 10.4 in.´lbf)
9. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a hexagon wrench (19 mm), hold the rack guide
spring cap rotating and using SST, torque the nut.
SST 09922-10010
Torque: 41 N´m (419 kgf´cm, 30 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Recheck the total preload.
Preload (turning):
0.6 - 1.2 N´m (6 - 12 kgf´cm, 5.2 - 10.4 in.´lbf)
(d) Remove the RH and LH rack ends.

R12040
SST
Fulcrum
Length
N00349
R15520
0 mm
6 mm
(0.24 in.)
R15519
SR-44
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
10. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
(b) Using a spanner, hold the steering rack steadily and using
SST, torque the rack end.
SST 09922-10010
Torque: 43 N´m (434 kgf´cm, 31 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Using a brass bar and hammer, stake the washer.
NOTICE:
Avoid any impact on the rack.
11. INSTALL RH AND LH BOOTS, CLAMPS AND CLIPS
(a) Install the rack boot.
NOTICE:
Be careful not to damage or twist the boot.
(b) Install the clamp screw, as shown in the illustration.
(c) Install the clip.
HINT:
Face the open ends of the clips outward/upward as shown in
the illustration, to avoid damage to the boot.
12. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe-in, torque the nut.
(See page SA-4)
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)

SR0KW-02
- STEERINGMANUAL STEERING GEAR
SR-45
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL MANUAL STEERING GEAR ASSEMBLY
Install the gear assembly from the LH of the vehicle.
2. INSTALL 2 GROMMETS AND BRACKETS
Torque the 2 bolts and nuts.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
3. CONNECT SLIDING YOKE (See page SR-20)
4. INSTALL COLUMN HOLE COVER
Torque the 4 nuts.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
5. CONNECT RH AND LH TIE ROD ENDS (See page SA-10)
6. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
HINT:
Do it with the front of the vehicle jacked up.
7. w/ Airbag:
CENTER SPIRAL CABLE (See page SR-20)
8. INSTALL STEERING WHEEL
(a) Install the wheel at straight-ahead position.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
9. CHECK STEERING WHEEL CENTER POINT
10. w/ Airbag:
TORQUE STEERING WHEEL SET NUT
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
11. w/ Airbag:
INSTALL STEERING WHEEL PAD (See page SR-20)
12. CHECK FRONT WHEEL ALIGNMENT (See page SA-4)