1996 TOYOTA TERCEL Service Repair Manual

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.

CL0650
Clutch Start Switch
CL0525
5.0 - 0.5 mm (0.196 + 0.020 in.)
- CLUTCHCLUTCH PEDAL
CL-3
698 Author
: Date
:
1996 TERCEL (RM440U)
6. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch ped-
al is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, adjust or replace the clutch start switch.
7. CHECK CONTINUITY OF CLUTCH START SWITCH
Check the continuity between terminals when the switch is ON
and OFF.
Switch positionCondition
ON (pushed)Continuity
OFF (free)No continuity
If continuity is not as specified, replace the switch.

CL05Q-04
Q06659
Filler Cap
Float
Reservoir Tank

Grommet
Slotted
Spring Pin
CylinderPistonPush RodWasherLock Nut Snap RingClevis Pin
Clip
Boot

Non-reusable partClevis
Clutch Line CL-4
- CLUTCHCLUTCH MASTER CYLINDER
699 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH MASTER CYLINDER
COMPONENTS

CL05R-01
Q06660
SST
- CLUTCHCLUTCH MASTER CYLINDER
CL-5
1996 TERCEL (RM440U)
REMOVAL
1. DRAW OUT FLUID WITH SYRINGE
2. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
3. REMOVE CLIP AND CLEVIS PIN
4. REMOVE 2 MOUNTING NUTS AND PULL OUT MAS-
TER CYLINDER
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)

CL05S-01
CL0659
CL0660
CL-6
- CLUTCHCLUTCH MASTER CYLINDER
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE RESERVOIR TANK
(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the reservoir tank and grommet.
2. REMOVE PUSH ROD
Pull off the boot, and using snap ring pliers, remove the snap
ring.
3. REMOVE PISTON

CL05T-01
CL0528
CL0652
Protrusion
1.5 - 3.5 mm
(0.059 - 0.138 in.)
- CLUTCHCLUTCH MASTER CYLINDER
CL-7
1996 TERCEL (RM440U)
REASSEMBLY
1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSERT PISTON INTO CYLINDER
3. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING
4. INSTALL RESERVOIR TANK
(a) Install the reservoir tank and a new grommet.
(b) Using a pin punch and hammer, drive in the slotted spring
pin.

CL05U-03
CL-8
- CLUTCHCLUTCH MASTER CYLINDER
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CL-5).
HINT:
After installation, bleed system and adjust clutch pedal.