1996 TOYOTA TERCEL clutch

Q06552
Q08461
AB
C
CC
A
Q06446
Q08159
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
MX-5
1996 TERCEL (RM440U)
14. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
(b) Remove the 2 bolts, springs and gasket.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the bolt, clamp and gasket.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(d) Disconnect the 2 rings and remove the exhaust front pipe.
15. REMOVE STARTER
Disconnect the connector and wire and remove the starter.
16. DISCONNECT SPEEDOMETER CABLE
17. REMOVE ENGINE REAR MOUNTING INSULATOR
Remove the 6 bolts and insulator.
Torque:
Bolt A: 78 N´m (800 kgf´cm, 58 ft´lbf)
Bolt B: 64 N´m (650 kgf´cm, 47 ft´lbf)
Bolt C: 90 N´m (920 kgf´cm, 67 ft´lbf)
18. DISCONNECT ENGINE LEFT MOUNTING BRACKET
FROM ENGINE LEFT MOUNTING INSULATOR
Remove the 2 bolts.
Torque: 48 N´m (490 kgf´cm, 36 ft´lbf)
19. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
20. REMOVE TRANSAXLE LOWER SIDE MOUNTING
BOLT
Remove the 4 bolts.
Torque:
14 mm head: 46 N´m (470 kgf´cm, 34 ft´lbf)
10 mm head: 7.4 N´m (75 kgf´cm, 65 in.´lbf)
21. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:

Align the input shaft with the clutch disc and install the
transaxle to the engine.

Install and torque the 7 bolts.
Torque:
Upper side mounting bolts: (See step 7)
Lower side mounting bolts: (See step 20)

MX07Z-04
Z18913
Clutch Release Bearing
Clutch Release Fork
Clutch Release Fork Boot
Clutch Release Fork Support
Oil Seal
Oil Seal
Transaxle Case
Oil Seal
Input Shaft Front Bearing
Output Shaft Cover
Output Shaft Front Bearing
Bearing Lock Plate
 Non-reusable partSpeedometer Driven Gear
Control Lever Housing
Support Bracket
Transaxle Case Receiver
Differential Case Assembly Outer Race Magnet
Plate Washer
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-7
719 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS

Q10103
Reverse Shift Arm
BracketReverse Shift Fork
Snap RingSnap Ring
Thrust Washer Reverse Idler Gear
Idler Gear Shaft
Ball (C151)Straight Screw Plug


BallSpringSeat


No.3 Shift Fork
(C151)

No.2 Shift Fork Shaft
Output Shaft Assembly
Shift HeadNo.1 Shift Fork Shaft
No.1 Shift Fork
No.2 Shift Fork
Lock Nut (C141)

5th Driven Gear
(C151)
x5
Spacer Snap Ring
Rear Bearing Retainer
Needle Roller Bearing
5th GearSynchronizer Ring
No.3 Hub Sleeve
Shifting Key
 Non-reusable part

Precoated partNo.3 Clutch
Hub
Snap Ring
Shifting Key SpringLock Nut (C151) 
Input Shaft AssemblySnap Ring
Spacer (C141)
No.3 Shift Fork Shaft Snap Ring (C151)
Snap RingSloted Spring Pin (C141)
(C151)
C151:
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-9
721 Author
: Date
:
1996 TERCEL (RM440U)

Q06523
Lock Bolt
Q06512
Q06531
SST
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-1 1
1996 TERCEL (RM440U)
9. REMOVE SHIFT AND SELECT LEVER SHAFT AS-
SEMBLY
(a) Remove the lock bolt.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(b) Remove the 4 bolts and pull out the shift and select lever
shaft assembly with the gasket.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N´m (200 kgf´cm, 14 ft´lbf)
10. REMOVE LOCK NUT
(a) Engage the gear double meshing.
(b) Using a hammer and chisel, loosen the staked part of the
nut.
(c) Remove the lock nut.
Torque: 118 N´m (1,200 kgf´cm, 87 ft´lbf)
(d) C141:
Remove the spacer.
(e) Disengage the gear double meshing.
11. C151:
REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the bolt from the No.3 shift fork.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(b) Remove the No.3 hub sleeve and shift fork.
12. C151:
REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.25 (0.0886)E2.49 (0.0980)
B2.31 (0.0909)F2.55 (0.1004)
C2.37 (0.0933)G2.61 (0.1028)
D2.43 (0.0957)--
(b) Using SST, remove the 5th gear, No.3 clutch hub, syn-
chronizer ring, needle roller bearings and spacer.
SST 09950-40010

Q06532
SST
Engine Side
Q06533
SST
Socket Wrench
N00174
SST
SST
Q06514
x5 MX-12
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
HINT:

Install the No.3 clutch hub and shifting keys to the hub
sleeve.

Install the shifting key springs under the shifting keys.
NOTICE:
At the time of reassembly, position the key springs so that
their end gaps are not in line.

Support the tip of the input shaft with a spacer or such
to raise the transaxle assembly.

Using SST and a hammer, drive in the No.3 hub sleeve
assembly with the No.3 shift fork.
SST 09612-2201 1
NOTICE:
At the time of reassembly, align the synchronizer ring slots
with the shifting keys.
13. C151:
REMOVE 5TH DRIVEN GEAR
Using SST and a socket wrench, remove the 5th driven gear.
SST 09950-40010
HINT:
At the time of reassembly, please refer to the following item.
Using SST, install the 5th driven gear.
SST 09309-12020
14. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and retainer.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
15. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.
HINT:
If it is difficult to remove and install the snap rings, pull up the
shafts.

N00047
CM0141
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-15
1996 TERCEL (RM440U)
(e) C151:
Using a magnetic finger, remove the 2 balls from the re-
verse shift fork.
(f) Remove the No.3 shift fork shaft and reverse shift fork.
(g) Pull out the No.1 shift fork shaft.
(h) Remove the No.1 and No.2 shift forks.
24. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER
FROM TRANSAXLE CASE
25. REMOVE DIFFERENTIAL CASE ASSEMBLY
HINT:
Before reassembly, inspect the differential side bearing pre-
load.
26. REMOVE MAGNET FROM TRANSAXLE CASE
27. REMOVE NO.3 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO.3 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs
from the No.3 clutch hub.

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.