1996 TOYOTA TERCEL clutch

- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-5
1996 TERCEL (RM440U)
3. MEASURE STALL TEST
The object of this test is to check the overall performance of the transaxle and the engine by measuring the
maximum engine speeds in the D and R positions.
NOTICE:

Do the test at normal operating ATF temperature 50 - 80 °C (122 - 176 °F).

Do not continuously run this test longer than 5 seconds.
(1) Chock the 4 wheels.
(2) Fully apply the parking brake.
(3) Connect the tachometer to the engine.
(4) Start the engine and check the idle speed.
(5) Keep your left foot pressing firmly on the brake pedal.
(6) Shift it into the D position. Press all the way down on the accelerator pedal. Quickly read the stall
speed RPM at this time.
Stall speed: 2,300 ± 200 rpm
(7) Do the same test in the R position.
Stall speed: 2,300 ± 200 rpm
EVALUATION
ProblemPossible cause
(a) Stall speed low in D and R positions.
Engine output may be insufficient

Stator one-way clutch is not operating properly
(b) Stall speed high in D position.

Line pressure too low

Forward clutch slipping

No.2 one-way clutch not operating properly

U/D one-way clutch not operating properly
(c) Stall speed high in R position.

Line pressure too low

Direct clutch slipping

1st and reverse brake slipping

U/D brake slipping
(d) Stall speed high in D and R positions.

Line pressure too low

Improper fluid level

U/D brake slipping
4. MEASURE TIME LAG TEST
When the shift lever is shifted while the engine is idling, there will be a certain lapse of time or lag before
the shock can be felt. This is used for checking the condition of the U/D direct clutch, forward clutch, direct
clutch and 1st and reverse brake.
NOTICE:

Do the test at normal operating ATF temperature 50 - 80 °C (122 - 176°F).

Make sure to allow 1 minute interval between the tests.

Take three measurements and take the average value.
(1) Fully apply the parking brake.
(2) Start the engine and check the idle speed.
Idling speed: 750 ± 50 rpm (In N position and A/C OFF)
(3) Shift the shift lever from the N to D position. Using a stop watch, measure the time it takes from
shifting the lever to the shock is felt.
Time lag: Less than 1.2 seconds
(4) In the same way, measure the time lag for N " R.
Time lag: Less than 1.5 seconds

AX-6
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U)
EVALUATION (If N " D or N " R time lag is longer than the specified):
ProblemPossible cause
N " D time lag is longer
Line pressure too low

Forward clutch worn
N " R time lag is longer

Line pressure too low

Direct clutch worn

1st and reverse brake worn
5. HYDRAULIC TEST
(a) Measure the line pressure.
(1) Warm up the ATF.
(2) Remove the transaxle case test plug and mount SST (See page AX-29).
SST 09992-00094 (09992-00150, 09992-00270)
NOTICE:

Do the test at normal operating ATF temperature 50 - 80°C (122 - 176 °F).

The line pressure test should always be carried out in pairs. One should observe the conditions
of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(3) Chock the 4 wheels.
(4) Fully apply the parking brake.
(5) Start the engine and check the idle speed.
(6) Keep your left foot pressing firmly on the brake pedal and shift into the D position.
(7) Measure the line pressure when the engine is idling.
(8) Fully depress the accelerator pedal. Quickly read the highest line pressure when the engine
speed reaches the stall speed.
NOTICE:
Release the accelerator pedal and stop the test if the wheels begin to rotate before the engine speed
reaches the specified stall speed.
(9) In the same way, do the test in the R position.
Specified line pressure:
D positionIdling
Stall373 - 422 kPa (3.8 - 4.3 kgf/cm2, 54 - 61 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
R position Idling
Stall549 - 706 kPa (5.6 - 7.2 kgf/cm2, 80 - 102 psi)
1,638 - 1,902 kPa (16.7 - 19.4 kgf/cm2, 238 - 276 psi)
(10) If the measured pressures are not up to specified values, recheck the throttle cable adjustment
and retest it.

- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-7
1996 TERCEL (RM440U)
EVALUATION
ProblemPossible cause
If the measured values at all positions are higher.

Throttle cable out of adjustment

Throttle valve defective

Regulator valve defective
If the measured values at all positions are lower.

Throttle cable out of adjustment

Throttle valve defective

Regulator valve defective

Oil pump defective

U/D one-way clutch not operating properly
If pressure is low in the D position only.

D position circuit fluid leakage

Forward clutch defective

U/D one-way clutch not operating properly
If pressure is low in the R position only.

R position circuit fluid leakage

Direct clutch defective

1st and reverse brake defective

U/D one-way clutch not operating properly
(b) Measure the governor pressure.
(1) Warm up the ATF.
(2) Remove the transaxle case test plug and mount SST (See page AX-29).
SST 09992-00094 (09992-00111, 09992-00270)
NOTICE:

Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176 °F).

Check that the throttle cable is adjusted within the specifications.

Check that the tire pressures are adjusted according to the specifications.
(3) Check the parking brake to see that it is not applied.
(4) Start the engine.
(5) Shift into the D position and measure the governor pressures at the speeds specified in the table.
EVALUATION
ProblemPossible cause
If governor pressure is defective.

Line pressure defective

Fluid leakage in governor pressure circuit

Governor valve operation defective
Vehicle speed (Reference)Governor pressure
30 km/h (19 mph)59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
60 km/h (37 mph)196 - 275 kPa (2.0 - 2.8 kgf/cm2, 28 - 40 psi)
90 km/h (56 mph)363 - 441 kPa (3.7 - 4.5 kgf/cm2, 53 - 64 psi)
6. ROAD TEST
NOTICE:
Do this test at normal operating ATF temperature 50 - 80 °C (122 - 176 °F).
(a) D position test.
Shift into the D position and while driving with the accelerator pedal held constantly at the throttle valve
fully open, check on the following points:
(1) 1 " 2, 2 " 3 and 3 "O/D up-shifts should take place, and shift points should conform to those
shown in the automatic shift schedule (See page SS-30).

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.

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).

AX086-04
Q07636
RH Drive ShaftStarterAir Cleaner
Assembly
Speedometer Cable
Rear Engine Mounting Insulator
Plug for Governor
Pressure Test
Tie Rod End

Snap Ring
LH Drive Shaft

Gasket
Clamp
Nut Cap

Cotter Pin O/D Solenoid
Connector
Snap
Ring
x6
Hole Plug
Torque Converter
Clutch
Clip
Control
Cable
Plug for Line Pressure Test
Oxygen Sensor

Gasket
Front Exhaust Pipe
Compression Spring
Engine Under Cover

Non-reusable part
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
AX-29
811 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS