1996 TOYOTA TERCEL wheel

SR17R-02
R12031
Torx ScrewScrew Case
R11976
Airbag
Connector
CorrectWrong
R11977
SST Matchmarks
- STEERINGNON-TIL T STEERING COLUMN
SR-13
1996 TERCEL (RM440U)
REMOVAL
1. w/ Airbag:
REMOVE STEERING WHEEL PAD
NOTICE:

If the airbag connector is disconnected with the igni-
tion switch at ON or ACC, DTCs will be recorded.

Never use airbag parts from another vehicle. When
replacing parts, replace with new ones.
(a) Place the front wheels facing straight ahead.
(b) Using a torx socket wrench, loosen the 2 torx screws.
HINT:
Loosen the 2 screws until the groove along the screw circumfer-
ence catches on the screw case.
(c) Pull the wheel pad from the steering wheel and discon-
nect the airbag connector.
CAUTION:

When storing the wheel pad, keep the upper surface
of the pad facing upward.

Never disassemble the wheel pad.
NOTICE:
When removing the wheel pad, take care not to pull the air-
bag wire harness.
2. w/o Airbag:
REMOVE STEERING WHEEL PAD
(a) Remove the screw.
(b) Remove the 3 clips.
3. REMOVE STEERING WHEEL
(a) Disconnect the connector.
(b) Remove the steering wheel set nut.
(c) Place matchmarks on the steering wheel and main shaft
assembly.
(d) Using SST, remove the wheel.
SST 09950-50010 (09951-05010, 09952-05010,
09953-05020, 09954-05020)

W01455
Torx ScrewScrew Case
- STEERINGNON-TIL T STEERING COLUMN
SR-21
1996 TERCEL (RM440U)
11. CENTER SPIRAL CABLE
(a) Check that the front wheels are facing straight ahead.
(b) Turn the cable counterclockwise by hand until it becomes
harder to turn the cable.
(c) Then rotate the cable clockwise about 2.5 turns to align
the green marks.
HINT:
The spiral cable turns clockwise about 2.5 turns to either left or
right of the center.
12. INSTALL STEERING WHEEL
(a) Align the matchmarks on the steering wheel and main
shaft assembly.
(b) Torque the steering wheel set nut.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(c) Connect the connector.
13. w/ Airbag:
INSTALL STEERING WHEEL PAD
NOTICE:

Make sure the wheel pad is installed with the speci-
fied torque.

If the wheel pad has been dropped, or there are
cracks, dents or other defects in the case or connec-
tor, replace the wheel pad with a new one.

When installing the wheel pad, take care that the wir-
ings do not interfere with other parts and that they are
not pinched between other parts.
(a) Connect the airbag connector.
(b) Install the wheel pad after confirming that the circumfer-
ence groove of the torx screws are caught on the screw
case.
(c) Using a torx socket wrench, torque the 2 screws.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
14. w/o Airbag:
INSTALL STEERING WHEEL PAD
15. CHECK STEERING WHEEL CENTER POINT

SR0KS-01
SR-36
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD
(See page SR-13)
3. REMOVE STEERING WHEEL
(See page SR-13)
4. DISCONNECT RH AND LH TIE ROD ENDS
(See page SA-10)
5. REMOVE COLUMN HOLE COVER
Remove the 4 nuts.
6. DISCONNECT SLIDING YOKE
(See page SR-13)
7. REMOVE 2 BRACKETS AND GROMMETS
Remove the 2 bolts and nuts.
8. REMOVE MANUAL STEERING GEAR ASSEMBLY
Remove the gear assembly from the LH side of the vehicle.

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.

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)

SR0KY-02
R11074
SST
SR4244
- STEERINGPOWER STEERING GEAR
SR-49
1996 TERCEL (RM440U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. w/ Airbag:
REMOVE STEERING WHEEL PAD (See page SR-13)
3. w/ Airbag:
REMOVE STEERING WHEEL (See page SR-13)
4. DISCONNECT RH AND LH TIE ROD ENDS (See page
SA-10)
5. REMOVE COLUMN HOLE COVER
Remove the 2 bolts and nut.
6. DISCONNECT SLIDING YOKE (See page SR-13)
7. REMOVE OXYGEN SENSOR
8. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts, compression springs and gasket.
(b) Remove the bolt, clamp and gasket.
(c) Disconnect the 2 rings.
9. REMOVE ENGINE REAR MOUNT INSULATOR
Remove the 6 bolts.
10. REMOVE ENGINE REAR MOUNT BRACKET
Remove the 2 bolts.
11. DISCONNECT 2 VACUUM HOSES
12. M/T:
DISCONNECT CONTROL CABLES
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
(c) Disconnect the 2 cables from the control lever housing
support bracket.
13. DISCONNECT PRESSURE FEED AND RETURN
TUBES
Using SST, disconnect the tube.
SST 09631-22020
14. DISCONNECT TUBE CLAMP
Remove the bolt.
15. REMOVE 2 BRACKETS AND GROMMETS
Remove the 2 bolts and nuts.
16. REMOVE PS GEAR ASSEMBLY
(a) Slide the gear assembly to the RH side of the vehicle.
(b) Slide the gear assembly to the LH side and pull it out.

R07337
Rack Groove
R11031
SST
Fulcrum
Length
R10934
Brass
Bar
F05319
SR4273
0 - 3 mm
(0 - 0.12 in.) SR-60
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
15. 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: 51 N´m (520 kgf´cm, 18 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 a hammer, stake the washer.
NOTICE:
Avoid any impact on the rack.
16. INSTALL RH AND LH RACK BOOTS, CLAMPS AND
CLIPS
(a) Ensure that the steering rack hole 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.
(b) Install the boot.
NOTICE:
Be careful not to damage or twist the boots.
(c) Tighten a new clamp, as shown in the illustration.

- STEERINGPOWER STEERING GEAR
SR-63
1996 TERCEL (RM440U)
9. INSTALL FRONT EXHAUST PIPE
(a) Connect the 2 rings.
(b) Install the bolt and clamp over a new gasket.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(c) Install the 2 bolts and compression springs over a new
gasket.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
10. INSTALL OXYGEN SENSOR
Install the sensor.
Torque: 44 N´m (450 kgf´cm, 32 ft´lbf)
11. CONNECT SLIDING YOKE (See page SR-20)
12. INSTALL COLUMN HOLE COVER
Torque the 2 bolts and nut.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
13. CONNECT RH AND LH TIE ROD ENDS
(See page SA-10)
14. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
HINT:
Do it with the front of the vehicle jacked up.
15. w/ Airbag:
CENTER SPIRAL CABLE (See page SR-20)
16. w/ Airbag:
INSTALL STEERING WHEEL
(a) Install the wheel at straight-ahead position.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
17. BLEED POWER STEERING SYSTEM
(See page SR-5)
18. CHECK STEERING WHEEL CENTER POINT
19. w/ Airbag:
TORQUE STEERING WHEEL SET NUT
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
20. w/ Airbag:
INSTALL STEERING WHEEL PAD (See page SR-20)
21. CHECK FRONT WHEEL ALIGNMENT
(See page SA-4)