1996 TOYOTA TERCEL clutch

ST1086
Z03210
(3)
(2)
(1)
Z15980
ST0659
ST0647
Hollow
Protrusion
ST-18
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
5. REMOVE DRIVE LEVER AND STARTER CLUTCH
WITH SHOCK ABSORBER FROM STARTER HOUS-
ING
6. REMOVE PLANETARY GEARS
Remove these parts from the shock absorber:
(1) Plate
(2) 3 planetary gears
(3) Plate washer
7. REMOVE STARTER CLUTCH
(a) Using a screwdriver, tap in the stop collar towards the
starter clutch.
(b) Using a screwdriver, pry off the snap ring.
(c) Remove the rear collar from the starter clutch.
8. REMOVE PLANET CARRIER SHAFT AND INTERNAL
GEAR
(a) Using snap ring pliers, remove the snap ring and plate
washer.
(b) Remove the planet carrier shaft and plate washer.
(c) Align the hollow of the internal gear with the protrusion in-
side the shock absorber, and remove the internal gear.

ST0661
Free
Lock
ST0667
P25604
Terminal C
Continuity Terminal 50
P25605
Continuity Terminal 50 Switch
Body
- STARTINGSTARTER (Planetary Type)
ST-21
1996 TERCEL (RM440U)
6. INSPECT CLUTCH AND GEAR
(a) Check the gear teeth on the planetary gear, internal gear
and starter clutch for wear or damage.
If the gear is damaged, replace it.
If the starter clutch teeth are damaged, replace the starter
clutch and also inspect the flywheel ring gear for wear or dam-
age.
(b) Check the starter clutch.
Rotate the clutch pinion gear clockwise and check that it
turns freely. Try to rotate the clutch pinion gear counter-
clockwise and check that it locks.
If necessary, replace the starter clutch.
7. INSPECT MAGNETIC SWITCH
(a) Check the plunger.
Push in the plunger and replace it. Check that it returns
quickly to its original position.
If necessary, replace the magnetic switch.
(b) Check the pull-in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminals 50 and C.
If there is no continuity, replace the magnetic switch.
(c) Check the hold-in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.

ST085-03
ST0646
Grease
ST0647
Hollow
Protrusion
ST0671
Planet Carrier Shaft
Plate Washer Shock Absorber
ST0672
ST0673
- STARTINGSTARTER (Planetary Type)
ST-25
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Use high temperature-resistant grease to lubricate the bear-
ings and sliding parts when assembling the starter.
1. INSTALL INTERNAL GEAR AND PLANET CARRIER
SHAFT
(a) Apply grease to the internal gear touching the shock ab-
sorber and planetary gears.
(b) Align the hollow of the internal gear with the protrusion in-
side the shock absorber.
(c) Insert and turn the internal gear so that it interlocks with
the shock absorber.
(d) Apply turbine oil to the center bearing.
(e) Apply grease to the plate washer, and install it to the plan-
et carrier shaft.
(f) Install the planet carrier shaft to the shock absorber.
(g) Using snap ring pliers, install the plate washer and snap
ring.
2. INSTALL STARTER CLUTCH
(a) Apply grease to the bushing and spline of the starter
clutch stop collar.
(b) Place the starter clutch and stop collar on the planet carri-
er shaft.
(c) Apply grease to the snap ring, and install it to the planet
carrier shaft groove.
(d) Using a vise, compress the snap ring.

ST0674
Z07229
Protrusion
Cutout
ST1086
ST1089
Cutout
Protrusion
ST0656
ST-26
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
(e) Hold the starter clutch, tap the planet carrier shaft and
install the stop collar onto the snap ring with a plastic-
faced hammer.
3. INSTALL PLANETARY GEARS
(a) Apply grease to the planetary gears and flange pin parts
of the planet carrier shaft.
(b) Install the plate washer and 3 planetary gears.
(c) Align the cutout of the plate with the protrusion inside the
shock absorber, and install the plate.
4. INSTALL DRIVE LEVER AND STARTER CLUTCH
WITH SHOCK ABSORBER
(a) Apply turbine oil to the bearing of the starter drive hous-
ing.
(b) Apply grease to the drive lever touching the starter pivot
part of the drive lever.
(c) Install the drive lever to the starter clutch.
(d) Align the protrusion of the shock absorber with the cutout
of the drive housing and install them.
5. PLACE ARMATURE INTO FIELD FRAME
6. INSTALL BRUSH HOLDER
(a) Place the brush holder in position on the armature.
(b) Using a screwdriver, hold the brush spring back, and con-
nect the brush into the brush holder. Connect the 4
brushes.
NOTICE:
Check that positive (+) lead wires are not grounded.
(c) Install a new O-ring to the groove of the field frame.
(d) Apply turbine oil to the bearing of the end cover.

ST086-01
P25503
Terminal C
Terminal 50
P25510
Disconnect
P25511
Disconnect
P25512
ST-28
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
TEST
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
1. DO PULL-IN TEST
(a) Disconnect the field coil lead from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
If the clutch pinion gear does not move, replace the magnetic
switch.
2. DO HOLD-IN TEST
While connected as above with the clutch pinion gear out, dis-
connect the negative (-) lead from terminal C. Check that the
clutch pinion gear remains out.
If the clutch pinion gear returns inward, replace the magnetic
switch.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the switch body. Check
that the clutch pinion gear returns inward.
If the clutch pinion gear does not return, replace the magnetic
switch.
4. INSPECT CLUTCH PINION GEAR CLEARANCE
(a) Connect the battery to the magnetic switch as shown.

ST1090
P25513
Terminal 30
Terminal 50
Ammeter
- STARTINGSTARTER (Planetary Type)
ST-29
1996 TERCEL (RM440U)
(b) Move the pinion gear toward the armature to remove
slack and measure the clearance between the pinion
gear end and stop collar.
Standard clearance: 1 - 5 mm (0.04 - 0.20 in.)
5. DO NO-LOAD PERFORMANCE TEST
(a) Connect the field coil lead to terminal C. Make sure the
lead is not grounded.
(b) Connect the battery and ammeter to the starter as shown.
(c) Check that the starter rotates smoothly and steadily with
the clutch pinion gear moving out. Check that the amme-
ter reads the specified current.
Specified current: At 11.5 V: 90 A or less

CL05O-03
- CLUTCHTROUBLESHOOTING
CL-1
696 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
1. Engine mounting (Loosen)-1.Engine mounting (Loosen)
2. Clutch disc (Runout is excessive)
-
CL-14
2.Clutch disc (Runout is excessive)
3. Clutch disc (Oily)
CL-14
CL-14
Clutch grabs/chatters
3.Clutch disc (Oily)
4. Clutch disc (Worn out)
CL-14
CL-14Clutch grabs/chatters4.Clutch disc (Worn out)
5. Clutch disc torsion rubber (Damaged)
CL-14
CL-145.Clutch disc torsion rubber (Damaged)
6. Clutch disc (Glazed)
CL 14
CL-146.Clutch disc (Glazed)
7. Diaphragm spring (Out of tip alignment)
CL 14
CL-14
1. Clutch line (Air in line)-
Clutch pedal spongy
1.Clutch line (Air in line)
2. Master cylinder cup (Damaged)
-
CL-4
Clutch edal s ongy2.Master cylinder cu (Damaged)
3. Release cylinder cup (Damaged)
CL 4
CL-9
1. Release bearing (Worn, dirty, or damaged)CL-14
Clutch noisy
1.Release bearing (Worn, dirty, or damaged)
2. Input shaft bearing (Worn or damaged)
CL-14
-Clutch noisy2.In ut shaft bearing (Worn or damaged)
3. Clutch disc torsion rubber (Damaged)CL-14
1. Clutch pedal (Free play out of adjustment)CL-21.Clutch edal (Free lay out of adjustment)
2. Clutch disc (Oily)
CL-2
CL-14
Cl t h li
2.Clutch disc (Oily)
3. Clutch disc (Worn out)
CL-14
CL-14Clutch slips3.Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
CL 14
CL-144.Dia hragm s ring (Damaged)
5. Pressure plate (Distortion)
CL 14
CL-145. Pressure late (Distortion)
6. Flywheel (Distortion)
CL 14
-
1 Clutchpedal (Freeplay out of adjustment)CL-21.Clutch pedal (Free play out of adjustment)
2 Clutch line (Air in line)CL-2
-2.Clutch line (Air in line)
3 Master cylinder cu
p(Damaged)
-
CL-43.Master cylinder cup (Damaged)
4. Release cylinder cu
p(Damaged)
CL-4
CL
-94.Release cylinder cup (Damaged)
5
. Input shaft bearing (Worn or damaged)
CL-9
-5.In ut shaft bearing (Worn or damaged)
6. Clutch disc (Out of true)
-
CL-14
Cl t h d t di
6.Clutch disc (Out of true)
7. Clutch disc (Runout is excessive)
CL-14
CL-14Clutch does not disengage7.Clutch disc (Runout is excessive)
8. Clutch disc (Lining broken)
CL-14
CL-148.Clutch disc (Lining broken)
9. Clutch disc (Dirty or burned)
CL-14
CL-149.Clutch disc (Dirty or burned)
10.Clutch disc (Oily)
CL 14
CL-1410.Clutch disc (Oily)
11. Clutch disc (Lack of spline grease)
CL 14
CL-1711. Clutch disc (Lack of s line grease)
12.Diaphragm spring (Damaged)
CL 17
CL-14gg(g)
13.Diaphragm spring (Out of tip alignment)CL-17gg( g)
14.Pressure plate (Distortion)CL-14

CL0649
Push Rod Play and Freeplay Adjust Point
Pedal Height
Adjust Point
Push Rod Play
Pedal HeightCL05P-04
CL0102
Pedal Freeplay
CL0512
25 mm (0.98 in.) or More
Full Stroke
End PositionRelease Point
CL-2
- CLUTCHCLUTCH PEDAL
697 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH PEDAL
INSPECTION
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from dash panel:
143.0 - 151.0 mm (5.629 - 5.944 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
Push in on the pedal until the beginning of clutch resistance is
felt.
Pedal freeplay: 5.0 - 15.0 mm (0.196 - 0.591 in.)
Gently push on the pedal until the resistance begins to in-
crease.
Push rod play at pedal top:
1.0-5.0 mm (0.039-0.196 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. CHECK CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point that the gear noise stops
(release point) up to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, perform the following opera-
tions.

Inspect pedal height.

Inspect push rod play and pedal freeplay.

Bleed the clutch line.

Inspect the clutch cover and disc.