1996 TOYOTA TERCEL lock

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.

Q06523
Lock Bolt
Q06512
Q06531
SST
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-1 1
1996 TERCEL (RM440U)
9. REMOVE SHIFT AND SELECT LEVER SHAFT AS-
SEMBLY
(a) Remove the lock bolt.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(b) Remove the 4 bolts and pull out the shift and select lever
shaft assembly with the gasket.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N´m (200 kgf´cm, 14 ft´lbf)
10. REMOVE LOCK NUT
(a) Engage the gear double meshing.
(b) Using a hammer and chisel, loosen the staked part of the
nut.
(c) Remove the lock nut.
Torque: 118 N´m (1,200 kgf´cm, 87 ft´lbf)
(d) C141:
Remove the spacer.
(e) Disengage the gear double meshing.
11. C151:
REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the bolt from the No.3 shift fork.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(b) Remove the No.3 hub sleeve and shift fork.
12. C151:
REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.25 (0.0886)E2.49 (0.0980)
B2.31 (0.0909)F2.55 (0.1004)
C2.37 (0.0933)G2.61 (0.1028)
D2.43 (0.0957)--
(b) Using SST, remove the 5th gear, No.3 clutch hub, syn-
chronizer ring, needle roller bearings and spacer.
SST 09950-40010

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.

WM0064
MX07J-03
WM0065
WM0066
N00053
SST MX-16
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
INSPECTION
1. C151:
INSPECT 5TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine
lapping compound between the synchronizer ring and gear
cone.
(c) Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(d) Check again the braking effect of the synchronizer ring.
(e) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. C151:
INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
3. REMOVE TRANSAXLE CASE RECEIVER
Remove the bolt and transaxle case receiver.
4. IF NECESSARY, REPLACE INPUT SHAFT FRONT
BEARING AND OIL SEAL
(a) Using SST, remove the bearing.
SST 09612-65014

N00160
SSTSST
Z16126
SST 15.8 ± 0.2 mm
Q07845
SST
N00162
SSTSST
N00056
Case Cover
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-17
1996 TERCEL (RM440U)
(b) Using SST, remove the oil seal.
SST 09612-65014
(c) Using SST and a hammer, install a new oil seal.
SST 09950- 60010 (09951- 00360), 09950- 70010
(09951-07150)
Drive in depth: 15.8 ± 0.2 mm (0.622 ± 0.008 in.)
(d) Coat the lip of the oil seal with MP grease.
(e) Using SST and a press, install a new bearing.
SST 09950- 60010 (09951- 00460), 09950- 70010
(09951-07150)
5. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT
BEARING AND OUTPUT SHAFT COVER
(a) Remove the bolt and bearing lock plate.
(b) Using SST, remove the bearing.
SST 09308-00010
(c) Remove the output shaft cover.
(d) Install the output shaft cover.
HINT:
Install the output shaft cover projection into the case side hol-
low.

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)

MX07N-01
WM0064
WM0065
WM0066
- MANUAL TRANSAXLEINPUT SHAFT
MX-23
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine
lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.

MX07R-01
WM0064
WM0065
WM0066
MT0071
ABC MX-30
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine
lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
3. INSPECT OUTPUT SHAFT
(a) Check the output shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Minimum outer diameter:
Part A: 32.970 mm (1.2980 in.)
Part B: 37.970 mm (1.4949 in.)
Part C: 31.970 mm (1.2587 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.