Page 813 of 1202
AX087-03
Q06569
Q06548
Q06571
Q06572
AX-30
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE THROTTLE CABLE
4. REMOVE GROUND CABLES
5. REMOVE UPPER SIDE MOUNTING BOLTS
(a) Remove the 2 upper side mounting bolts.
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
(b) Remove the upper side starter bolt.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
6. INSTALL ENGINE SUPPORT FIXTURE
7. RAISE VEHICLE
8. REMOVE UNDER COVER
9. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-18)
10. DISCONNECT SPEEDOMETER CABLE
11. DISCONNECT CONTROL CABLE
(a) Remove the clip from the control cable.
(b) Disconnect the control cable from the lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
12. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
13. DISCONNECT O/D SOLENOID CONNECTOR
14. DISCONNECT OIL COOLER HOSE FROM PIPE
15. REMOVE STARTER
(a) Disconnect the cable and connector.
(b) Remove the starter with the bolt.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
Page 814 of 1202
Q08079
Q08081
Q07892
Q08080A
BA
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
AX-31
1996 TERCEL (RM440U)
16. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
Torque: 44 N´m (450 kgf´cm, 32 ft´lbf)
(b) Remove the bolts and springs from the exhaust manifold
and front exhaust pipe.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the clamp.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(d) Remove the front exhaust pipe and gaskets.
HINT:
Replace the used gaskets with new ones.
17. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
(a) Remove the converter cover.
(b) Turn the crankshaft to gain access and remove the 6 bolts
with holding the crankshaft pulley set bolt a wrench.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
18. SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
19. DISCONNECT LH ENGINE MOUNTING BRACKET
Remove the 2 mounting bolts.
Torque: 49 N´m (490 kgf´cm, 36 ft´lbf)
20. REMOVE ENGINE REAR MOUNTING
(a) Remove the rear mounting insulator through bolt.
Torque: 65 N´m (650 kgf´cm, 48 ft´lbf)
(b) Remove the 5 bolts and rear mounting insulator.
Torque:
Bolt A: 80 N´m (800 kgf´cm, 59 in´lbf)
Bolt B: 92 N´m (920 kgf´cm, 69 ft´lbf)
Page 822 of 1202
F03984
R15511
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA-5
821 Author: Date:
1996 TERCEL (RM440U)
5. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheels.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
(c) Coat the threads of the nuts with engine oil.
(d) Temporarily install the 2 nuts.
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
Adjusting value: 0°06' - 0°30'
(f) Tighten the nuts.
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
(g) Install the front wheels.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
Camber
Left-right error-0°20' ± 45'
45' (0.75°) or less
HINT:
Try to adjust the camber to the center value.
Adjusting value for the set bolts is 6' - 30' (0.1° - 0.5°).
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 842 of 1202
SA1W8-02
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA-25
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. REMOVE FLEXIBLE HOSE
Remove the bolt and disconnect the flexible hose from the shock absorber.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
3. w/ ABS:
DISCONNECT ABS SPEED SENSOR WIRE HARNESS
Remove the bolt and disconnect the ABS speed sensor wire harness from the shock absorber.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
4. DISCONNECT SHOCK ABSORBER FROM STEERING KNUCKLE
Remove the 2 nuts and bolts and disconnect the shock absorber from steering knuckle,
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
HINT:
Coat the nut's threads with engine oil.
5. REMOVE SHOCK ABSORBER AND COIL SPRING
(a) Remove the 3/4 nuts on the upper side of the shock absorber.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Remove the shock absorber with the coil spring.
Page 860 of 1202
R12355
Pedal Freeplay
BR4228
Pedal Reserve Distance
- BRAKEBRAKE PEDAL
BR-7
881 Author: Date:
1996 TERCEL (RM440U)
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance, as shown.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake.
(b) With the engine running, depress the pedal and measure
the pedal reserve distance.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf):
w/o ABS: More than 60 mm (2.36 in.)
w/ ABS: More than 55 mm (2.17 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.
Page 868 of 1202
BR2237
BR0RJ-01
BR2238
GOOD NO GOOD
1st2nd3rd
- BRAKEBRAKE BOOSTER ASSEMBLY
BR-15
889 Author: Date:
1996 TERCEL (RM440U)
BRAKE BOOSTER ASSEMBLY
ON-VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.
