1996 TOYOTA TERCEL Gear oil

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

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)

MX07K-03
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-19
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly.
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.

MX07O-02
D02999
Engine Side
Z08629
N00067
N00068
- MANUAL TRANSAXLEINPUT SHAFT
MX-25
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply gear oil to the needle roller bearings.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Using a press, install the 3rd gear and No.2 hub sleeve
assembly.
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
02.30 (0.0906)32.48 (0.0976)
12.36 (0.0929)42.54 (0.1000)
22.42 (0.0953)52.60 (0.1024)
(b) Using a screwdriver and hammer, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MX-21)

N00070
SM0049
SST
SM0050
MX-26
- MANUAL TRANSAXLEINPUT SHAFT
1996 TERCEL (RM440U)
5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER
BEARING, SPACER, 4TH GEAR AND REAR BALL
BEARING
(a) Apply gear oil to the needle roller bearings.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Using SST and a press, install the rear ball bearing.
SST 09608-00071
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.29 (0.0902)D2.47 (0.0972)
B2.35 (0.0925)E2.53 (0.0996)
C2.41 (0.0949)F2.59 (0.1020)
(b) Using a screwdriver and hammer, install the snap ring.
7. INSPECT 4TH GEAR THRUST CLEARANCE
(See page MX-21)

MX07S-03
CM0009
Engine Side
N00077
N00078
N00079
MX-32
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the No.1 clutch hub and shifting keys to the No.1
hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL BALL, THRUST WASHER, 1ST GEAR,
NEEDLE ROLLER BEARING, SYNCHRONIZER RING
AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT
SHAFT
(a) Install the ball to the shaft.
(b) Fit the thrust washer groove securely over the locking ball
when installing the thrust on the shaft.
(c) Apply gear oil to the needle roller bearing.
(d) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(e) Using a press, install the 1st gear and No.1 hub sleeve.

N00080
N00083
N00084
N00086
SST
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-33
1996 TERCEL (RM440U)
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.50 (0.0984)D2.68 (0.1055)
B2.56 (0.1008)E2.74 (0.1079)
C2.62 (0.1031)F2.80 (0.1102)
(b) Using a screwdriver and hammer, install the snap ring.
4. INSPECT 1ST GEAR THRUST CLEARANCE
(See page MX-28)
5. INSTALL SYNCHRONIZER RING, 2ND GEAR,
NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR
(a) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(b) Apply gear oil to the needle roller bearing.
(c) Install the 2nd gear.
(d) Using a press, install the 3rd driven gear.
6. INSPECT 2ND GEAR THRUST CLEARANCE
(See page MX-28)
7. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN
GEAR AND REAR BALL BEARING
(a) Install the output gear spacer.
(b) Using SST and a press, install the 4th driven gear and
rear ball bearing.
SST 09608-00071

MX07U-03
Q06511

Oil Seal
Plate Washer

Outer Race and Side Bearing
Speedometer Drive Gear
Straight Pin

Side Bearing and Outer Race

Oil Seal
Ring Gear Plate Washer Differential Case Pinion Shaft
Pinion Gear
Thrust Washer
Side Gear
Thrust Washer

Non-reusable partx6
- MANUAL TRANSAXLEDIFFERENTIAL CASE
MX-35
747 Author
: Date
:
1996 TERCEL (RM440U)
DIFFERENTIAL CASE
COMPONENTS