Page 817 of 1202
AT0952
SST
AX0S7-01
AT0953
AT3306
Hold
TurnLock
Free
AT2821
AT2820
AX-34
- AUTOMATIC TRANSAXLE (A242L)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
816 Author: Date:
1996 TERCEL (RM440U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE-WAY CLUTCH
(a) Install SST in the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
(c) With the torque converter clutch held upright, inspect the
clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch. Replace
the converter clutch if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, and measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification, replace the drive
plate.
Torque: 88 N´m (900 kgf´cm, 65 ft´lbf)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correct by reori-
enting the installation of the converter.
HINT:
Mark the position of the converter clutch to ensure the correst
installation.
Page 823 of 1202
F01195
Bolt
Adjusting
ValueSet Bolt
15'
30'Adjusting Bolt90105-15001 90105-15004 90105-15005 90105-15006
45'
1°00'
1°15'
1°30'121212121 Dot 2 Dots 3 Dots
W00533
W00533
SA-6
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
822 Author: Date:
1996 TERCEL (RM440U)
If the camber is not within the specification, using the table be-
low, estimate of how much additional camber adjustment will be
required, and select the camber adjusting bolt.
(i) Follow the above mentioned steps again. Between step
(b) and (c), exchange 1 or 2 selected bolts.
HINT:
When exchanging the 2 bolts, exchange 1 bolt for each time.
6. ADJUST TOE-IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right rack ends an equal amount to adjust
the toe-in.
Toe-in
(total)A + B: 0.1° ± 0.2°
C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
HINT:
Try to adjust the toe-in to the center value.
Make sure that the lengths of the left and right rack ends
are the same.
Tie rod end length difference: 1.5 mm (0.059 in.) or
less
(d) Torque the tie rod end lock nuts.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
(e) Place the boots on the seat and install the clamps to them.
HINT:
Make sure that the boots are not twisted.
Page 827 of 1202
SA114-03
R11682
F03986
F03987
SA-10
- SUSPENSION AND AXLEFRONT AXLE HUB
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. w/ ABS
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
3. REMOVE FRONT BRAKE CALIPER AND DISC
(a) Remove the 2 bolts and brake caliper from the steering
knuckle.
Torque: 88 N´m (900 kgf´cm, 65 in.´lbf)
(b) Support the brake caliper securely.
(c) Remove the disc.
4. CHECK BACKLASH IN BEARING SHAFT DIRECTION
Using a dial indicator, check the backlash near the center of the
axle hub, and check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
5. CHECK AXLE HUB DEVIATION
Using a dial indicator, check the deviation at the surface of the
axle hub outside the hub bolt.
Maximum: 0.05 mm (0.0020 in.)
If the deviation exceeds the maximum, replace the axle hub.
6. REMOVE DRIVE SHAFT LOCK NUT
(a) Install the brake disc and caliper.
(b) Remove the cotter pin and lock cap.
(c) With applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
(d) Remove the brake caliper and disc.
7. LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK AB-
SORBER
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
HINT:
Do not remove the 2 bolts.
Coat the nut's thread with engine oil.
Page 835 of 1202
SA128-02
FA1535
SST
F03986
SA-18
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
REMOVAL
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed. Therefore, if it is
absolutely necessary to place the vehicle weight on
the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the sensor rotor
serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. M/T:
REMOVE LH ENGINE UNDER COVER
3. DRAIN TRANSAXLE OIL (M/T) OR ATF (A/T)
4. w/ ABS:
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
5. REMOVE DRIVE SHAFT LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) While applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
6. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE (See page SA-10)
7. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See page SA-10)
8. DISCONNECT DRIVE SHAFT FROM AXLE HUB
NOTICE:
Be careful not to damage the drive shaft boot and inner oil
seal.
Page 839 of 1202
Z12938
RH
LH
R09908
SA-22
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
7. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Make sure the boot are on the shaft groove.
(b) Set the drive shaft length to the standard.
Standard length
RH785.1 ± 5.0 mm (30.909 ± 0.197 in.)
LH544.9 ± 5.0 mm (21.421 ± 0.197 in.)
(c) Place the 4 new boot clamps to the boots.
(d) Bend the band, and lock it with a screwdriver.
8. RH DRIVE SHAFT:
ASSEMBLE DYNAMIC DAMPER CLAMP
(a) Be sure the damper is on the shaft groove.
(b) Set the distance, as shown.
Distance: 361.4 ± 5.0 mm (14.335 ± 0.197 in.)
(c) Place a new damper clamp to the damper.
(d) Bend the band and lock it in the same procedure for the
boot clamp assembly.
9. INSTALL SNAP RING
Using a snap ring expander, install a new snap ring to the in-
board joint shaft.
10. CHECK DRIVE SHAFT (See page SA-20)
Page 857 of 1202
BR0RA-07
BR5038
BR5040
BR5039
BR3885
BR-4
- BRAKEBRAKE FLUID
878 Author: Date:
1996 TERCEL (RM440U)
BRAKE FLUID
BLEEDING
HINT:
If any work is done on the brake system or air in the brake lines
is suspected, bleed the system of air.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Fluid: SAEJ1703 or FMVSS No.116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or the reservoir
becomes empty, bleed the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outer holes with your finger and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the air out of the
brake line for each wheel.
Page 859 of 1202
R12354
Stop Light Switch
Push Rod
Pedal Height
BR4980
A
BR1DT-01
BR-6
- BRAKEBRAKE PEDAL
880 Author: Date:
1996 TERCEL (RM440U)
BRAKE PEDAL
ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
EZ Grade:
143.0 - 153.0 mm (5.630 - 6.024 in.)
Except EZ Grade:
140.0 - 150.0 mm (5.512 - 5.906 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 - 2.4 mm (0.020 - 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check the stop lights come on when the brake pedal is de-
pressed, and go off when the brake pedal is released.
(l) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the brack ped-
al stopper has been adjusted correctly, the pedal freeplay will
meet the specifications.
Page 861 of 1202
BR0786
BR0RC-06
BR5045
BR-8
- BRAKEPARKING BRAKE LEVER
882 Author: Date:
1996 TERCEL (RM440U)
PARKING BRAKE LEVER
ON-VEHICLE INSPECTION
1. CHECK PARKING BRAKE LEVER TRAVEL
Pull the parking brake lever all the way up, and count the num-
ber of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):
5 - 8 clicks
2. IF NECESSARY, ADJUST PARKING BRAKE
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
For shoe clearance adjustment, see step 2 on page BR-33.
(a) Remove the console box.
(b) Loosen the lock nut and turn the adjusting nut until the le-
ver travel is correct.
(c) Tighten the lock nut.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(d) Install the console box.
