1996 TOYOTA TERCEL torque spec

CH0HC-01
P04218
P13695
29 mm
Socket
Wrench
P04209
SST (A)
Turn SST (B)
P04210
SST (C)
- CHARGINGGENERATOR
CH-15
1996 TERCEL (RM440U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation direction.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) Type A
Install the 4 nuts.
Torque: 4.5 N´m (46 kgf´cm, 40 in.´lbf)
(d) Type B:
Install the 2 nuts and 2 bolts.
Torque: 4.5 N´m (46 kgf´cm, 40 in.´lbf)
4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820-63010
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

CL063-03
Q06681
Flywheel Side
CL0291
1.4
MatchmarksSST 7 3
6
2.58
Q06392
SST
N00415
CL0653
- CLUTCHCLUTCH UNIT
CL-17
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them.
SST 09301-00210
(b) Align the matchmark on the clutch cover and flywheel.
(c) Torque the bolts on the clutch cover in the order shown.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
HINT:
Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333-00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to these parts:

Release fork and hub contact point

Release fork and push rod contact point

Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887-01706 (100 g).
4. INSTALL RELEASE BEARING AND FORK TO TRANS-
AXLE
Install the bearing to the release fork, and then install them to
the transaxle.
5. INSTALL TRANSAXLE TO ENGINE
(See page MX-6)

MX0B1-02
Q07828
FIPG
N00038
N00039
MX-10
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE RELEASE FORK AND BEARING
HINT:
Apply molybdenum disulphide lithium base grease
(See page CL-17).
2. REMOVE SPEEDOMETER DRIVEN GEAR
Remove the driven gear lock plate set bolt and driven gear.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
3. REMOVE BACK-UP LIGHT SWITCH
Torque: 40 N´m (410 kgf´cm, 30 ft´lbf)
4. REMOVE CONTROL LEVER HOUSING SUPPORT
BRACKET
Remove the 3 bolts and bracket.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
5. REMOVE SELECTING BELLCRANK ASSEMBLY
Remove the 2 bolts and selecting bellcrank assembly.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
6. REMOVE TRANSMISSION CASE COVER
(a) Remove the 9 bolts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
(b) Carefully tap the projection of the transmission case cov-
er with a brass bar and hammer and remove the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent
7. C151:
INSPECT 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 - 0.57 mm (0.0039 - 0.0224 in.)
Maximum clearance: 0.65 mm (0.0256 in.)
8. C151:
INSPECT 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.
Standard clearance:
0.015 - 0.058 mm (0.0006 - 0.0023 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.

N00102
MX07W-04
MT0083
N00172
Case
Side Matchmarks MX-38
- MANUAL TRANSAXLEDIFFERENTIAL CASE
1996 TERCEL (RM440U)
REASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the correct thrust washers and side gears.
Refer to the table below, select thrust washers which will
ensure that the backlash is within the specification. Try to
select washers of the same size for both sides.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thickness mm (in.)Thickness mm (in.)
1.50 (0.0591)1.65 (0.0650)
1.55 (0.0610)1.70 (0.0669)
1.60 (0.0630)1.75 (0.0689)
(b) Install the thrust washers and side gears in the differential
case.
(c) Install the pinion shaft.
(d) Using a dial indicator, check the side gear backlash.
Measure the side gear backlash while holding one pinion
gear toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specification, install a thrust
washer of different thickness.
(e) Using a pin punch and hammer, install the straight pin
through the case and hole in the pinion shaft.
(f) Stake the differential case.
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surface of the differential case.
(b) Heat the ring gear in boiling water.
(c) Carefully remove the ring gear from the water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the differential case and contact the
ring gear.
(e) Install the 6 set bolts. Tighten each set bolt uniformly, at
a time in succession. Torque the bolts.
Torque: 124 N´m (1,260 kgf´cm, 91 ft´lbf)

N00173
SST
SST
CM0061
MT0092
SST
- MANUAL TRANSAXLEDIFFERENTIAL CASE
MX-39
1996 TERCEL (RM440U)
3. INSTALL SIDE BEARING
(a) Install the speedometer drive gear to the RH side.
(b) Using SST and a press, install new side bearings to the
both sides of the case.
SST 09350-32014 (09351-32090, 09351-32120)
4. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD
(a) Install the differential case assembly to the transaxle
case.
(b) Install the transmission case.
(c) Install and torque the case bolts.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(d) Using SST and a torque wrench, measure the preload.
SST 09564-3201 1
Preload (at starting):
New bearing
0.8 - 1.6 N´m (8 - 16 kgf´cm, 6.9 - 13.9 in.´lbf)
Reused bearing
0.5 - 1.0 N´m (5 - 10 kgf´cm, 4.3 - 8.7 in.´lbf)
If the preload is not within the specification, remove the trans-
mission case side outer race of the side bearing with SST (See
page MX-36).
(e) Select another shim.
HINT:
The preload will change by approx. 0.3 - 0.4 N´m (3 - 4 kgf´cm,
2.6 - 3.5 in.´lbf) corresponding to a change of 0.05 mm in shim
thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.10 (0.0827)L2.60 (0.1024)
B2.15 (0.0846)M2.65 (0.1043)
C2.20 (0.0866)N2.70 (0.1063)
D2.25 (0.0886)P2.75 (0.1083)
E2.30 (0.0906)Q2.80 (0.1102)
F2.35 (0.0925)R2.85 (0.1122)
G2.40 (0.0945)S2.90 (0.1142)
H2.45 (0.0965)T2.95 (0.1161)
J2.50 (0.0984)U3.00 (0.1181)
K2.55 (0.1004)--

AX0RI-02
(b) Check the idle speed.
(e) Check the shift linkage. (d) Check the throttle cable mark.
(f) Check the park/neutral position switch.
Check the engine and the torque converter clutch. (c) Check the fluid level and fluid condition.
STALL TEST
TIME LAG TEST PRELIMINARY CHECK
ROAD TEST HYDRAULIC TEST
MATRIX CHART (a) Check the tire inflation.
Measure the line pressure and make a basic check of fluid circuit.
Check if trouble lies within automatic transaxle. If noise or vibration occurs, the possible cause could
be with the compressor, engine, drive shaft and tires, etc. Check the automatic transaxle (each clutch, brake and gear) for wear.
(See page AX-10) AX-2
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
TROUBLESHOOTING
1. GENERAL INFORMATION
(a) Troubles occurring with the automatic transaxle can be caused by either the engine or the transaxle
itself. These two areas should be checked before proceeding with troubleshooting.
(b) Troubleshooting should begin with the simplest operation, working up in order of difficulty, but first de-
termine whether the trouble lies within the engine or transaxle.
(c) Proceed with the inspection as follows:

AT8103
Neutral Basic Line
Groove
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-5
1996 TERCEL (RM440U)
(2) Using an ohmmeter, check continuity between each
terminal shown below when the shift lever is put in
each position.
(h) Adjust the shift control cable.
(1) Remove the engine under cover.
(2) Loosen the nut on the control shaft lever.
(3) Push the control shaft lever fully toward the right
side of the vehicle.
(4) Return the lever 2 notches to the NEUTRAL posi-
tion.
(5) Set the shift lever to the N position.
(6) While holding the lever lightly toward the ºRº posi-
tion side, tighten the swivel nut.
(i) Adjust the park/neutral position switch.
If the engine will start with the shift selector in any position other
than the N or P position, adjustment is required.
(1) Loosen the park/neutral position switch bolts and
set the shift selector to the N position.
(2) Align the groove with neutral basic line.
(3) Hold the switch in the position and tighten the bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(j) Inspect the idle speed.
Idle speed:
750 ± 50 rpm (In the N position and A/C OFF)
3. MEASURE STALL TEST
The object of this test is to check the overall performance of the transaxle and the engine by measuring the
maximum engine speeds in the D and R positions.
NOTICE:
Do the test at normal operating fluid temperature 50 - 80°C (122 - 176 °F).
Do not continuously run this test longer than 5 seconds.
(1) Check the front and rear wheels.
(2) Connect the tachometer to the engine.
(3) Fully apply the parking brake.

AX-8
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
EVALUATION
ProblemPossible cause
If governor pressure defect.
 Line pressure defect
 Fluid leakage in governor pressure circuit
 Governor valve operation defect
Vehicle speed (Reference)Governor pressure
30 km/h (19 mph)59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
60 km/h (37 mph)186 - 365 kPa (1.9 - 2.7 kgf/cm2, 27 - 38 psi)
90 km/h (56 mph)353 - 431 kPa (3.6 - 4.4 kgf/cm2, 51 - 63 psi)
6. ROAD TEST
NOTICE:
Do this test at normal fluid temperature 50 - 80 °C (122 - 176 °F).
(a) D position test.
Shift into the D position and while driving with the accelerator pedal held constant at the throttle valve
fully open, check on the following points:
(1) Check to seethat the 1"2 and 2"3 up-shifts take placeand also that the shift points conform
to those shown in the automatic shift schedule (See page SS-28).
EVALUATION
ProblemPossible cause
If there is no 1 - 2 up-shift. Governor valve is defective
 1 - 2 shift valve is stuck
If there is no 2 - 3 up-shift. 1 - 2 shift valve is stuck
If the shift point is defective.Throttle cable out of adjustment
 Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, etc. are defective
(2) In the same way, check the shock and slip at 1 " 2 and 2 " 3 up-shifts.
EVALUATION
ProblemPossible cause
If the shock is severe.
 Line pressure is too high
 Accumulator is defective
 Check ball is defective
(3) Run in the 3rd gear of the D position, check the abnormal noise and vibration.
HINT:
Check for the cause of abnormal noise and vibration must be made with extreme care as they could also
be due to imbalance in the drive shaft, differential, tires and torque converter clutch, etc.
(4) While running in the 3rd gear of the D position, check that the possible kick-down vehicle speed
limits for the 3 " 1 and 3 " 2 kick-down conform to those indicated in the automatic shift sched-
ule (See page SS-28).
EVALUATION
ProblemPossible cause
If the possible kick-down vehicle speed limit is defective. Throttle cable out of adjustment
 Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, etc. are defective
(5) Check the abnormal shock and slip at kick-down.
(6) While running at about 60 km/h (37 mph) in the 3rd gear of the D position, release your foot from
the accelerator pedal and shift into the L position. Then check if the 2 "1 down-shift point con-
forms to that indicated in the automatic shift schedule (See page SS-28).
(b) Inspect the lock-up mechanism.
(1) Drive in the D position at a steady speed (Lock-up ON) of about 65 km/h (40 mph).
(2) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly.