1996 TOYOTA TERCEL Transmission

- PREPARATIONENGINE MECHANICAL
PP-3
50 Author
: Date
:
1996 TERCEL (RM440U)
(09248-05410)Valve Lifter Press
(09248-05420)Valve Lifter Stopper
09309-37010Transmission Bearing ReplacerCrankshaft front oil seal
09330-00021Companion Flange Holding ToolCrankshaft pulley
09550-10012Replacer Set ºBº
(09252-10010)No. 1 Replacer HandleValve guide bushing
Spark plug tube gasket
(09556-10010)Differential Drive Pinion Front
Bearing RemoverSpark plug tube gasket
09816-30010Oil Pressure Switch SocketKnock sensor
Oil pressure switch
09843-18020Diagnosis Check Wire
09950-50010Puller C Set
(09951-05010)Hanger 150Crankshaft pulley
(09952-05010)Slide ArmCrankshaft pulley
(09953-05020)Center Bolt 150Crankshaft pulley

PP3IW-01
- PREPARATIONMANUAL TRANSAXLE
PP-35
82 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE
SST (Special Service Tools)
09201-10000Valve Guide Bushing Remover &
Replacer SetSpeedometer driven gear oil seal
(09201-01080)Valve Guide Bushing Remover &
Replacer 8
09308-00010Oil Seal PullerOutput shaft front bearing
09309-120205th Driven Gear Replacer
09350-32014TOYOTA Automatic Transmission
Tool Set
(09351-32090)Oil Seal Remover & ReplacerDifferential side bearing
(09351-321 11)Side Bearing Race ReplacerDifferential side bearing oil seal
(Transmission case side)
(09351-32120)Overdrive Bearing ReplacerDifferential side bearing
(09351-32130)Handle
(09351-32150)Oil Seal ReplacerDifferential side bearing oil seal
(Transaxle case side)
09564-3201 1Differential Preload Adaptor
09608-00071Drive Pinion Rear Bearing Cone
ReplacerInput shaft rear ball bearing
4th driven gear and rear ball bearing

PP-36
- PREPARATIONMANUAL TRANSAXLE
83 Author
: Date
:
1996 TERCEL (RM440U)
09612-2201 1Tilt Handle Bearing ReplacerNo. 3 hub sleeve assembly
09612-65014Steering Worm Bearing PullerInput shaft front bearing and oil seal
Differential taper roller bearing outer
race
09921-00010Spring Tension ToolSpeedometer driven gear oil seal
09950-00020Bearing Remover
09950-00030Bearing Remover Attachment
09950-4001 1Puller B Set
09950-60010Replacer Set
(09951-00360)Replacer 36Input shaft front oil seal
Differential case side bearing
(09951-00460)Replacer 46Input shaft front bearing
(09951-00620)Replacer 62Output shaft front bearing
09950-60020Replacer Set No.2
(09951-00680)Replacer 68Differential taper roller bearing outer
race (Transaxle case side)
(09951-00710)Replacer 71Differential taper roller bearing outer
race (Transmission case side)

PP14U-01
- PREPARATIONMANUAL TRANSAXLE
PP-41
1996 TERCEL (RM440U)
SSM (Special Service Materials)
08826-00090Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)Transmission case x Transaxle case
Transmission case x Case cover
08833-00080Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalentStraight screw plug
Control shaft cover bolt

PP3IX-01
PP-42
- PREPARATIONAUTOMATIC TRANSAXLE (A132L)
89 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A132L)
SST (Special Service Tools)
09201-10000Valve Guide Bushing Remover &
Replacer SetSpeedometer driven gear oil seal
(09201-01080)Valve Guide Bushing Remover &
Replacer 8
09308-00010Oil Seal PullerSide gear shaft oil seal
09350-32014TOYOTA Automatic Transmission
Tool Set
(09351-32010)One-way Clutch Test Tool
(09351-32020)Stator Stopper
(09351-32130)Handle
(09351-32150)Oil Seal Replacer
09921-00010Spring Tension ToolSpeedometer driven gear oil seal
09992-00095Automatic Transmission Oil
Pressure Gauge SetLine pressure

PP3IY-01
- PREPARATIONAUTOMATIC TRANSAXLE (A242L)
PP-47
94 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A242L)
SST (Special Service Tools)
09201-10000Valve Guide Bushing Remover &
Replacer SetSpeedometer driven gear oil seal
(09201-01080)Valve Guide Bushing Remover &
Replacer 8
09308-00010Oil Seal PullerSide gear shaft oil seal
09350-32014TOYOTA Automatic Transmission
Tool Set
(09351-32010)One-way Clutch Test Tool
(09351-32020)Stator Stopper
(09351-32130)Handle
(09351-32150)Oil Seal Replacer
09921-00010Spring Tension ToolSpeedometer driven gear oil seal
09992-00095Automatic Transmission Oil
Pressure Gauge SetLine pressure

PP3IZ-01
PP-52
- PREPARATIONSUSPENSION AND AXLE
99 Author
: Date
:
1996 TERCEL (RM440U)
SUSPENSION AND AXLE
SST (Special Service Tools)
09223-00010Cover & Seal ReplacerRear suspension
09223-15020Oil Seal & Bearing ReplacerFront axle
09308-00010Oil Seal PullerFront axle
Rear axle
09309-36010Transmission Rear Bearing
ReplacerFront drive shaft
09316-2001 1Transfer Bearing ReplacerFront drive shaft
09520-00031Rear Axle Shaft PullerFront axle
09550-10013Replacer Set ºBºRear axle
(09553-10010)Differential Side Bearing
Replacer
(09557-1001 1)Differential Drive Pinion
Front Bearing Replacer
09608-10010Steering Knuckle Oil Seal
ReplacerFront axle
09608-16042Front Hub Bearing Adjusting ToolFront drive shaft
(09608-02021)Bolt & Nut

SS0KP-02
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-25
155 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE
SERVICE DATA
Input shaft roller bearing journal diameterMin.24.970 mm (0.9831 in.)
Input shaft 3rd gear journal diameterMin.30.970 mm (1.2193 in.)
Input shaft 4th gear journal diameterMin.28.970 mm (1.1405 in.)
Input shaft 5th gear journal diameter (for C151)Min.24.870 mm (0.9791 in.)
Input shaft runoutMax.0.05 mm (0.0020 in.)
Output shaft roller bearing journal diameterMin.32.970 mm (1.2980 in.)
Output shaft 1st gear journal diameterMin.37.970 mm (1.4949 in.)
Output shaft 2nd gear journal diameterMin.31.970 mm (1.2587 in.)
Output shaft runoutMax.0.05 mm (0.0020 in.)
Gear thrust clearance 1st STD
Max.0.10 - 0.40 mm (0.0039 - 0.0157 in.)
0.45 mm (0.0177 in.)
Gear thrust clearance 2nd STD
Max.0.10 - 0.45 mm (0.0039 - 0.0177 in.)
0.50 mm (0.0197 in.)
Gear thrust clearance 3rd STD
Max.0.10 - 0.35 mm (0.0039 - 0.0138 in.)
0.40 mm (0.0157 in.)
Gear thrust clearance 4th STD
Max.0.10 - 0.55 mm (0.0039 - 0.0217 in.)
0.60 mm (0.0236 in.)
Gear thrust clearance 5th (for C151) STD
Max.0.10 - 0.57 mm (0.0039 - 0.0224 in.)
0.65 mm (0.0256 in.)
1st, 2nd, 3rd, 4th and 5th (for C151) gear radial clearance STD
Max.0.015 - 0.058 mm (0.0006 - 0.0023 in.)
0.070 mm (0.0028 in.)
Shift fork to hub sleeve clearance Max.1.0 mm (0.039 in.)
Synchronizer ring to gear clearance Min.0.6 mm (0.024 in.)
Drive in depth
Input shaft front oil seal
Speedometer driven gear oil seal
Control shaft cover oil seal
Select inner lever slotted spring pin
No. 1 shift inner lever slotted spring pin
No. 2 shift inner lever slotted spring pin
Transmission case oil seal
Transaxle case oil seal
15.8 ± 0.2 mm (0.622 ± 0.008 in.)
25 mm (0.98 in.)
1.0 - 2.0 mm (0.039 - 0.079 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
2.4 ± 0.3 mm (0.094 ± 0.012 in.)
1.9 ± 0.3 mm (0.075 ± 0.012 in.)
Differential side gear backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Differential side gear thrust washer thickness1.50 mm (0.0591 in.)
1.55 mm (0.0610 in.)
1.60 mm (0.0630 in.)
1.65 mm (0.0650 in.)
1.70 mm (0.0669 in.)
1.75 mm (0.0689 in.)
Differential side bearing preload (at starting) (for use with SST)
New bearing
Reused bearing
0.8 - 1.6 N´m (8 - 16 kgf´cm, 6.9 - 13.9 in.´lbf)
0.5 - 1.0 N´m (5 - 10 kgf´cm, 4.3 - 8.7 in.´lbf)