1996 TOYOTA TERCEL torque

Q06532
SST
Engine Side
Q06533
SST
Socket Wrench
N00174
SST
SST
Q06514
x5 MX-12
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
HINT:

Install the No.3 clutch hub and shifting keys to the hub
sleeve.

Install the shifting key springs under the shifting keys.
NOTICE:
At the time of reassembly, position the key springs so that
their end gaps are not in line.

Support the tip of the input shaft with a spacer or such
to raise the transaxle assembly.

Using SST and a hammer, drive in the No.3 hub sleeve
assembly with the No.3 shift fork.
SST 09612-2201 1
NOTICE:
At the time of reassembly, align the synchronizer ring slots
with the shifting keys.
13. C151:
REMOVE 5TH DRIVEN GEAR
Using SST and a socket wrench, remove the 5th driven gear.
SST 09950-40010
HINT:
At the time of reassembly, please refer to the following item.
Using SST, install the 5th driven gear.
SST 09309-12020
14. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and retainer.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
15. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.
HINT:
If it is difficult to remove and install the snap rings, pull up the
shafts.

MT0057
Q06516
C141 Only
Q06524
Z00668
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-13
1996 TERCEL (RM440U)
16. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
17. REMOVE SNAP RING FROM NO.2 SHIFT FORK
SHAFT
Using 2 screwdrivers and a hammer, remove the snap ring.
18. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING
AND BALL
(a) Using a hexagon wrench, remove the 4 plugs.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
C141 Plug, As Shown:
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) Using a magnetic finger, remove the 3 seats, springs and
balls.
19. REMOVE STRAIGHT SCREW PLUG (C141) OR LOCK
BALL ASSEMBLY (C151)
Using a hexagon wrench, remove the straight screw plug
(C141) or lock ball assembly (C151).
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
20. REMOVE TRANSMISSION CASE
(a) Remove the 16 bolts.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(b) Carefully tap the transmission case with a plastic hammer
and remove it.

MT0094
FIPG
Q08153
MT0093Align Alignment Mark
Q06515
C151 Only
N00045
MX-14
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent
21. REMOVE REVERSE IDLER GEAR, THRUST WASHER
AND SHAFT
22. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and bracket.
Torque: 17 N´m (175 kgf´cm, 13 ft´lbf)
HINT:
Install the reverse idler gear, thrust washer and shaft, as shown.
23. REMOVE SHIFT FORK AND SHIFT FORK SHAFT
(a) Using 2 screwdrivers and a hammer, tap out the 3 (C151)
or 2 (C141) snap rings.
(b) Remove the 3 set bolts.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(c) C141:
Using a pin punch and hammer, remove the slotted spring
pin from the reverse shift fork.
(d) Remove the No.2 shift fork shaft and shift head.

Q07846
SSTSST
Q07552
SST
SST
25 mm
N00060
N00061
MX-18
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
(e) Using SST and a press, install a new bearing.
SST 09950- 60010 (09951- 00620), 09950- 70010
(09951-07150)
(f) Install the bearing lock plate and torque the bolt.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
6. INSTALL TRANSAXLE CASE RECEIVER
Install the transaxle case receiver and torque the bolt.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
7. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN
GEAR OIL SEAL
(a) Using SST, remove the oil seal.
SST 09921-00010
(b) Using SST, install a new oil seal.
SST 09201- 10000 (09201- 01080), 09950- 70010
(09951-07150)
Drive in depth: 25 mm (0.98 in.)
(c) Coat the lip of oil seal with MP grease.
8. C151:
IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Using a hexagon wrench, remove the straight screw plug.
(b) Using a pin punch and hammer, remove the slotted spring
pin.
(c) Replace the reverse restrict pin.
(d) Using a pin punch and hammer, install the slotted spring
pin.
(e) Apply sealant to the plug threads.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Using a hexagon wrench, install the straight screw plug.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

N00102
MX07W-04
MT0083
N00172
Case
Side Matchmarks MX-38
- MANUAL TRANSAXLEDIFFERENTIAL CASE
1996 TERCEL (RM440U)
REASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the correct thrust washers and side gears.
Refer to the table below, select thrust washers which will
ensure that the backlash is within the specification. Try to
select washers of the same size for both sides.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thickness mm (in.)Thickness mm (in.)
1.50 (0.0591)1.65 (0.0650)
1.55 (0.0610)1.70 (0.0669)
1.60 (0.0630)1.75 (0.0689)
(b) Install the thrust washers and side gears in the differential
case.
(c) Install the pinion shaft.
(d) Using a dial indicator, check the side gear backlash.
Measure the side gear backlash while holding one pinion
gear toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specification, install a thrust
washer of different thickness.
(e) Using a pin punch and hammer, install the straight pin
through the case and hole in the pinion shaft.
(f) Stake the differential case.
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surface of the differential case.
(b) Heat the ring gear in boiling water.
(c) Carefully remove the ring gear from the water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the differential case and contact the
ring gear.
(e) Install the 6 set bolts. Tighten each set bolt uniformly, at
a time in succession. Torque the bolts.
Torque: 124 N´m (1,260 kgf´cm, 91 ft´lbf)

N00173
SST
SST
CM0061
MT0092
SST
- MANUAL TRANSAXLEDIFFERENTIAL CASE
MX-39
1996 TERCEL (RM440U)
3. INSTALL SIDE BEARING
(a) Install the speedometer drive gear to the RH side.
(b) Using SST and a press, install new side bearings to the
both sides of the case.
SST 09350-32014 (09351-32090, 09351-32120)
4. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD
(a) Install the differential case assembly to the transaxle
case.
(b) Install the transmission case.
(c) Install and torque the case bolts.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(d) Using SST and a torque wrench, measure the preload.
SST 09564-3201 1
Preload (at starting):
New bearing
0.8 - 1.6 N´m (8 - 16 kgf´cm, 6.9 - 13.9 in.´lbf)
Reused bearing
0.5 - 1.0 N´m (5 - 10 kgf´cm, 4.3 - 8.7 in.´lbf)
If the preload is not within the specification, remove the trans-
mission case side outer race of the side bearing with SST (See
page MX-36).
(e) Select another shim.
HINT:
The preload will change by approx. 0.3 - 0.4 N´m (3 - 4 kgf´cm,
2.6 - 3.5 in.´lbf) corresponding to a change of 0.05 mm in shim
thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.10 (0.0827)L2.60 (0.1024)
B2.15 (0.0846)M2.65 (0.1043)
C2.20 (0.0866)N2.70 (0.1063)
D2.25 (0.0886)P2.75 (0.1083)
E2.30 (0.0906)Q2.80 (0.1102)
F2.35 (0.0925)R2.85 (0.1122)
G2.40 (0.0945)S2.90 (0.1142)
H2.45 (0.0965)T2.95 (0.1161)
J2.50 (0.0984)U3.00 (0.1181)
K2.55 (0.1004)--

AX0RI-02
(b) Check the idle speed.
(e) Check the shift linkage. (d) Check the throttle cable mark.
(f) Check the park/neutral position switch.
Check the engine and the torque converter clutch. (c) Check the fluid level and fluid condition.
STALL TEST
TIME LAG TEST PRELIMINARY CHECK
ROAD TEST HYDRAULIC TEST
MATRIX CHART (a) Check the tire inflation.
Measure the line pressure and make a basic check of fluid circuit.
Check if trouble lies within automatic transaxle. If noise or vibration occurs, the possible cause could
be with the compressor, engine, drive shaft and tires, etc. Check the automatic transaxle (each clutch, brake and gear) for wear.
(See page AX-10) AX-2
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
TROUBLESHOOTING
1. GENERAL INFORMATION
(a) Troubles occurring with the automatic transaxle can be caused by either the engine or the transaxle
itself. These two areas should be checked before proceeding with troubleshooting.
(b) Troubleshooting should begin with the simplest operation, working up in order of difficulty, but first de-
termine whether the trouble lies within the engine or transaxle.
(c) Proceed with the inspection as follows:

AT8103
Neutral Basic Line
Groove
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-5
1996 TERCEL (RM440U)
(2) Using an ohmmeter, check continuity between each
terminal shown below when the shift lever is put in
each position.
(h) Adjust the shift control cable.
(1) Remove the engine under cover.
(2) Loosen the nut on the control shaft lever.
(3) Push the control shaft lever fully toward the right
side of the vehicle.
(4) Return the lever 2 notches to the NEUTRAL posi-
tion.
(5) Set the shift lever to the N position.
(6) While holding the lever lightly toward the ºRº posi-
tion side, tighten the swivel nut.
(i) Adjust the park/neutral position switch.
If the engine will start with the shift selector in any position other
than the N or P position, adjustment is required.
(1) Loosen the park/neutral position switch bolts and
set the shift selector to the N position.
(2) Align the groove with neutral basic line.
(3) Hold the switch in the position and tighten the bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(j) Inspect the idle speed.
Idle speed:
750 ± 50 rpm (In the N position and A/C OFF)
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 fluid temperature 50 - 80°C (122 - 176 °F).
Do not continuously run this test longer than 5 seconds.
(1) Check the front and rear wheels.
(2) Connect the tachometer to the engine.
(3) Fully apply the parking brake.