1996 TOYOTA TERCEL key

MX07L-01
Q06510
Needle Roller Bearing
Synchronizer Ring
No.2 Clutch HubInput Shaft
Needle Roller Bearing
4th Gear No.2 Hub Sleeve
3rd Gear
Shifting Key
Shifting Key Spring
Synchronizer Ring
Snap Ring
Rear Ball Bearing Snap Ring
MX-20
- MANUAL TRANSAXLEINPUT SHAFT
732 Author
: Date
:
1996 TERCEL (RM440U)
INPUT SHAFT
COMPONENTS

CM0064
SST
CM0141
MX-22
- MANUAL TRANSAXLEINPUT SHAFT
1996 TERCEL (RM440U)
6. REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR,
SYNCHRONIZER RING AND NEEDLE ROLLER BEAR-
ING
Using SST and a press, remove the No.2 hub sleeve assembly,
3rd gear, synchronizer ring and needle roller bearings.
SST 09950-00020
7. REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO.2 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs
from the No.2 clutch hub.

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)

MX07P-01
Q06509
Needle Roller Bearing
1st Gear
No.1 Hub Sleeve
Shifting Key
No.1 Clutch Hub
Synchronizer RingOutput Shaft Assembly Ball
Thrust Washer
Synchronizer Ring
Needle Roller Bearing
2nd GearShifting Key Spring
Snap Ring
3rd Driven Gear
Output Gear Spacer
4th Driven Gear
Rear Ball Bearing
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-27
739 Author
: Date
:
1996 TERCEL (RM440U)
OUTPUT SHAFT
COMPONENTS

MT0063
SST
N00076
CM0142
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-29
1996 TERCEL (RM440U)
(b) Using SST and a press, remove the 3rd driven gear and
2nd gear.
SST 09950-00020
(c) Remove the needle roller bearing and synchronizer ring.
5. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, remove the snap ring.
6. REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR,
SYNCHRONIZER RING, NEEDLE ROLLER BEARING,
THRUST WASHER AND BALL
(a) Using a press, remove the No.1 hub sleeve assembly, 1st
gear and synchronizer ring.
(b) Remove the needle roller bearing, thrust washer and ball.
7. REMOVE NO.1 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO.1 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs
from the No.1 clutch hub.

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