1996 TOYOTA TERCEL Service Repair Manual

WM0064
MX07J-03
WM0065
WM0066
N00053
SST MX-16
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
INSPECTION
1. C151:
INSPECT 5TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine
lapping compound between the synchronizer ring and gear
cone.
(c) Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(d) Check again the braking effect of the synchronizer ring.
(e) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. C151:
INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
3. REMOVE TRANSAXLE CASE RECEIVER
Remove the bolt and transaxle case receiver.
4. IF NECESSARY, REPLACE INPUT SHAFT FRONT
BEARING AND OIL SEAL
(a) Using SST, remove the bearing.
SST 09612-65014

N00160
SSTSST
Z16126
SST 15.8 ± 0.2 mm
Q07845
SST
N00162
SSTSST
N00056
Case Cover
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-17
1996 TERCEL (RM440U)
(b) Using SST, remove the oil seal.
SST 09612-65014
(c) Using SST and a hammer, install a new oil seal.
SST 09950- 60010 (09951- 00360), 09950- 70010
(09951-07150)
Drive in depth: 15.8 ± 0.2 mm (0.622 ± 0.008 in.)
(d) Coat the lip of the oil seal with MP grease.
(e) Using SST and a press, install a new bearing.
SST 09950- 60010 (09951- 00460), 09950- 70010
(09951-07150)
5. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT
BEARING AND OUTPUT SHAFT COVER
(a) Remove the bolt and bearing lock plate.
(b) Using SST, remove the bearing.
SST 09308-00010
(c) Remove the output shaft cover.
(d) Install the output shaft cover.
HINT:
Install the output shaft cover projection into the case side hol-
low.

Q07846
SSTSST
Q07552
SST
SST
25 mm
N00060
N00061
MX-18
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
(e) Using SST and a press, install a new bearing.
SST 09950- 60010 (09951- 00620), 09950- 70010
(09951-07150)
(f) Install the bearing lock plate and torque the bolt.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
6. INSTALL TRANSAXLE CASE RECEIVER
Install the transaxle case receiver and torque the bolt.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
7. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN
GEAR OIL SEAL
(a) Using SST, remove the oil seal.
SST 09921-00010
(b) Using SST, install a new oil seal.
SST 09201- 10000 (09201- 01080), 09950- 70010
(09951-07150)
Drive in depth: 25 mm (0.98 in.)
(c) Coat the lip of oil seal with MP grease.
8. C151:
IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Using a hexagon wrench, remove the straight screw plug.
(b) Using a pin punch and hammer, remove the slotted spring
pin.
(c) Replace the reverse restrict pin.
(d) Using a pin punch and hammer, install the slotted spring
pin.
(e) Apply sealant to the plug threads.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Using a hexagon wrench, install the straight screw plug.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

MX07K-03
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-19
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly.
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.

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

MX07M-01
Q05793
3rd Gear
4th Gear
N00065
Q06518
C141:C151:
SSTSocket Wrench
SST
- MANUAL TRANSAXLEINPUT SHAFT
MX-21
1996 TERCEL (RM440U)
DISASSEMBLY
1. INSPECT 3RD AND 4TH GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
3rd gear: 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
4th gear: 0.10 - 0.55 mm (0.0039 - 0.0217 in.)
Maximum clearance:
3rd gear: 0.40 mm (0.0157 in.)
4th gear: 0.60 mm (0.0236 in.)
2. INSPECT 3RD AND 4TH GEARS RADIAL CLEAR-
ANCE
Using a dial indicator, measure the radial clearance between
the gear and shaft.
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.
3. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, remove the snap ring.
4. REMOVE REAR BALL BEARING, 4TH GEAR, NEEDLE
ROLLER BEARING, SPACER AND SYNCHRONIZER
RING FROM INPUT SHAFT
(a) Using SST, a socket wrench (C141 only) and press, re-
move the rear ball bearing.
SST 09950-00020
(b) Remove the 4th gear, needle roller bearings, spacer and
synchronizer ring.
5. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, remove the snap ring.

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.

MX07N-01
WM0064
WM0065
WM0066
- MANUAL TRANSAXLEINPUT SHAFT
MX-23
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine
lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.