1996 TOYOTA TERCEL manual transmission

SS0KQ-04
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-27
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Engine 17 mm head
14 mm head
10 mm head64
46
7.4650
470
7547
34
65 in.´lbf
Engine left mounting bracket x Insulator4849036
Engine rear mounting insulator x Body7880058
Engine rear mounting insulator x Bracket B bolt
C bolt64
90650
92047
67
Front exhaust pipe clamp set bolt1919014
Front exhaust pipe x Exhaust manifold6263046
Starter x Transaxle3940029
Clutch release cylinder x Transaxle121209
Shift lever assembly x Body121209
Grommet retainer x Body4.95043 in.´lbf
Retainer x Body4.95043 in.´lbf
Output shaft front bearing lock plate set bolt1111 58
Transmission case x Transaxle case2930022
Reverse shift arm bracket1717513
Straight screw plug (Reverse restrict pin) (C151)
Straight screw plug13
13130
1309
9
Straight screw plug (Shift fork shaft)2525018
Straight screw plug (Lock ball assembly) (C151)
Straight screw plug (C141)39
39400
40029
29
Reverse idler gear shaft lock bolt2930022
Rear bearing retainer2728020
Output shaft lock nut11 81,20087
Shift fork and shift head x Shift fork shaft1616012
Shift and select lever assembly2020014
Transmission case x Transmission case cover1818513
Back-up light switch4041030
Filler and drain plugs3940029
Ring gear x Differential case1241,26091
Speedometer driven gear1111 58
Control lever housing support bracket x Transmission case1111 58
Selecting bellcrank assembly x Transmission case2525018
Shift and select lever shaft assembly lock bolt2930022
Transaxle case receiver x Transaxle case1111 58
No. 1 and No. 2 oil receiver pipe1717513

S00840
- DIAGNOSTICSENGINE
DI-5
1996 TERCEL (RM440U)Terminal No.
Connection / Voltage or ResistanceCondition
7Bus + Line / Pulse generationDuring transmission
4Chassis Ground - Body Ground / 1 W or lessAlways
5Signal Ground - Body Ground / 1 W or lessAlways
16Battery Positive - Body Ground / 9 - 14 VAlways
HINT:
If your display shows ºUNABLE TO CONNECT TO VEHICLEº
when you have connected the cable of the OBD II scan tool or
TOYOTA hand-held tester to DLC3, turned the ignition switch
ON and operated the scan tool, there is a problem on the ve-
hicle side or tool side.

If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.

If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool its self, so consult the Service Department listed in
the tool's instruction manual.
2. Normal Mode:
INSPECT DIAGNOSIS
(a) Check the MIL.
(1) The MIL comes on when the ignition switch is turned
ON and the engine is not running.
HINT:
If the MIL does not light up, troubleshoot the combination meter.
(2) When the engine started, the MIL should go off. If
the lamp remains on, the diagnosis system has de-
tected a malfunction or abnormality in the system
(b) Check the DTC.
NOTICE:
TOYOTA hand-held tester only: When the diagnosis sys-
tem is switched from the normal mode to the check mode,
it erases all DTC and freeze frame data recorded in the nor-
mal mode. So before switching modes, always check the
DTC and freeze frame data, and note them down.
(1) Prepare the OBD II scan tool (complying with SAE
J 1978) or TOYOTA hand-held tester.
(2) Connect the OBD II scan tool or TOYOTA hand-
held tester to DLC3 in the fuse box at the lower left
of the instrument panel.
(3) Turn the ignition switch ON and turn the OBD II scan
tool or TOYOTA hand-held tester switch ON.
(4) Use the OBD II scan tool or TOYOTA hand-held
tester to check the DTC and freezed frame data;
note them down (For operating instructions, see the
OBD II scan tool's instruction book.).
(5) See page DI-13 to confirm the details of the
DTC.

P19552
TOYOTA Hand-Held Tester
DLC3EM0K9-03
P20244
- ENGINE MECHANICALIGNITION TIMING
EM-9
430 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII
SCAN TOOL
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester or OBDII scan
tool to the DLC3.
(c) Please refer to the TOYOTA hand-held tester or OBDII
scan tool operator's manual for further details.
3. CONNECT TIMING LIGHT
4. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843-18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
10° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral
position)
(c) Remove the SST from the DLC1.
SST 09843-18020
5. FURTHER CHECK IGNITION TIMING
Check that the ignition timing advances.
Ignition timing:
7 - 17° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral posi-
tion)
HINT:
The timing mark moves in a range between 7° and 17°.
6. DISCONNECT TIMING LIGHT
7. DISCONNECT TOYOTA HAND- HELD TESTER OR
OBDII SCAN TOOL

Q06552
Q08461
AB
C
CC
A
Q06446
Q08159
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
MX-5
1996 TERCEL (RM440U)
14. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
(b) Remove the 2 bolts, springs and gasket.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the bolt, clamp and gasket.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(d) Disconnect the 2 rings and remove the exhaust front pipe.
15. REMOVE STARTER
Disconnect the connector and wire and remove the starter.
16. DISCONNECT SPEEDOMETER CABLE
17. REMOVE ENGINE REAR MOUNTING INSULATOR
Remove the 6 bolts and insulator.
Torque:
Bolt A: 78 N´m (800 kgf´cm, 58 ft´lbf)
Bolt B: 64 N´m (650 kgf´cm, 47 ft´lbf)
Bolt C: 90 N´m (920 kgf´cm, 67 ft´lbf)
18. DISCONNECT ENGINE LEFT MOUNTING BRACKET
FROM ENGINE LEFT MOUNTING INSULATOR
Remove the 2 bolts.
Torque: 48 N´m (490 kgf´cm, 36 ft´lbf)
19. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
20. REMOVE TRANSAXLE LOWER SIDE MOUNTING
BOLT
Remove the 4 bolts.
Torque:
14 mm head: 46 N´m (470 kgf´cm, 34 ft´lbf)
10 mm head: 7.4 N´m (75 kgf´cm, 65 in.´lbf)
21. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:

Align the input shaft with the clutch disc and install the
transaxle to the engine.

Install and torque the 7 bolts.
Torque:
Upper side mounting bolts: (See step 7)
Lower side mounting bolts: (See step 20)

Z18912
Oil Receiver Pipe
Straight Screw Plug (C141)


Slotted Spring Pin (C151)
Outer Race
Plate Washer Reverse Restrict Pin (C151)
Oil Receiver Pipe
x13 Transmission Case
 Lock Ball Assembly (C151)


Back-Up Light Switch
Lock Bolt
Breather Plug
Shift and Select Lever
Shaft Assembly
Selecting Bellcrank Assembly
Oil Seal
x9
Transmission Case
Cover (C141) Drain Plug
 Non-reusable part

Precoated partTransmission Case
Cover (C151)
x9
Gasket Gasket
Filler Plug


Straight Screw Plug
Straight Screw Plug (C141)
Gasket MX-8
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
720 Author
: Date
:
1996 TERCEL (RM440U)

MX0B1-02
Q07828
FIPG
N00038
N00039
MX-10
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE RELEASE FORK AND BEARING
HINT:
Apply molybdenum disulphide lithium base grease
(See page CL-17).
2. REMOVE SPEEDOMETER DRIVEN GEAR
Remove the driven gear lock plate set bolt and driven gear.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
3. REMOVE BACK-UP LIGHT SWITCH
Torque: 40 N´m (410 kgf´cm, 30 ft´lbf)
4. REMOVE CONTROL LEVER HOUSING SUPPORT
BRACKET
Remove the 3 bolts and bracket.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
5. REMOVE SELECTING BELLCRANK ASSEMBLY
Remove the 2 bolts and selecting bellcrank assembly.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
6. REMOVE TRANSMISSION CASE COVER
(a) Remove the 9 bolts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
(b) Carefully tap the projection of the transmission case cov-
er with a brass bar and hammer and remove the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent
7. C151:
INSPECT 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 - 0.57 mm (0.0039 - 0.0224 in.)
Maximum clearance: 0.65 mm (0.0256 in.)
8. C151:
INSPECT 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.
Standard clearance:
0.015 - 0.058 mm (0.0006 - 0.0023 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.

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.

MX07V-03
Z16129
SST
MT0081
Matchmarks
MT0083
MT0084
N00098
SST MX-36
- MANUAL TRANSAXLEDIFFERENTIAL CASE
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
(a) Using SST, remove the bearings from both sides of the
case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00360)
(b) Remove the speedometer drive gear from the RH side.
2. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and case.
(b) Remove the 6 bolts.
(c) Using a plastic hammer, remove the ring gear from the
case.
3. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear
while holding one pinion toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specification, install the correct
thrust washer to the side gears.
4. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, remove the pinion shaft
straight pin.
(b) Remove the pinion shaft from the case.
(c) Remove the 2 pinion gears and side gears with the 4
thrust washers from each gear.
5. Transmission Case Side:
IF NECESSARY, REPLACE OIL SEAL AND SIDE
BEARING OUTER RACE
(a) Using a screwdriver and hammer, remove the oil seal.
(b) Using SST, remove the outer race and plate washer.
SST 09612-65014
(c) Place the plate washer into the case.