1996 TOYOTA TERCEL Service Repair Manual

CM0066
AB
C
D
CM0013
MX-24
- MANUAL TRANSAXLEINPUT SHAFT
1996 TERCEL (RM440U)
3. INSPECT INPUT SHAFT
(a) Check the input shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the in-
put shaft journal surface.
Minimum outer diameter:
Part A (C151): 24.870 mm (0.9791 in.)
Part B: 28.970 mm (1.1405 in.)
Part C: 30.970 mm (1.2193 in.)
Part D: 24.970 mm (0.9831 in.)
If the outer diameter is less than the minimum, replace the input
shaft.
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 in.)
If the runout exceeds the maximum, replace the input shaft.

MX07O-02
D02999
Engine Side
Z08629
N00067
N00068
- MANUAL TRANSAXLEINPUT SHAFT
MX-25
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply gear oil to the needle roller bearings.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Using a press, install the 3rd gear and No.2 hub sleeve
assembly.
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
02.30 (0.0906)32.48 (0.0976)
12.36 (0.0929)42.54 (0.1000)
22.42 (0.0953)52.60 (0.1024)
(b) Using a screwdriver and hammer, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MX-21)

N00070
SM0049
SST
SM0050
MX-26
- MANUAL TRANSAXLEINPUT SHAFT
1996 TERCEL (RM440U)
5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER
BEARING, SPACER, 4TH GEAR AND REAR BALL
BEARING
(a) Apply gear oil to the needle roller bearings.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Using SST and a press, install the rear ball bearing.
SST 09608-00071
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.29 (0.0902)D2.47 (0.0972)
B2.35 (0.0925)E2.53 (0.0996)
C2.41 (0.0949)F2.59 (0.1020)
(b) Using a screwdriver and hammer, install the snap ring.
7. INSPECT 4TH GEAR THRUST CLEARANCE
(See page MX-21)

MX07P-01
Q06509
Needle Roller Bearing
1st Gear
No.1 Hub Sleeve
Shifting Key
No.1 Clutch Hub
Synchronizer RingOutput Shaft Assembly Ball
Thrust Washer
Synchronizer Ring
Needle Roller Bearing
2nd GearShifting Key Spring
Snap Ring
3rd Driven Gear
Output Gear Spacer
4th Driven Gear
Rear Ball Bearing
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-27
739 Author
: Date
:
1996 TERCEL (RM440U)
OUTPUT SHAFT
COMPONENTS

MX07Q-01
Q05794
2nd Gear
1st Gear
SM0137
CM0065
SST
N00074
MX-28
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
DISASSEMBLY
1. INSPECT 1ST AND 2ND GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear: 0.10 - 0.40 mm (0.0039 - 0.0157 in.)
2nd gear: 0.10 - 0.45 mm (0.0039 - 0.0177 in.)
Maximum clearance:
1st gear: 0.45 mm (0.0177 in.)
2nd gear: 0.50 mm (0.0197 in.)
2. INSPECT 1ST AND 2ND 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 REAR BALL BEARING, 4TH DRIVEN GEAR
AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT
(a) Using SST and a press, remove the rear ball bearing and
4th driven gear.
SST 09950-00020
(b) Remove the output gear spacer.
4. REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE
ROLLER BEARING AND SYNCHRONIZER RING
(a) Shift the No.1 hub sleeve into the 1st gear.

MT0063
SST
N00076
CM0142
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-29
1996 TERCEL (RM440U)
(b) Using SST and a press, remove the 3rd driven gear and
2nd gear.
SST 09950-00020
(c) Remove the needle roller bearing and synchronizer ring.
5. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, remove the snap ring.
6. REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR,
SYNCHRONIZER RING, NEEDLE ROLLER BEARING,
THRUST WASHER AND BALL
(a) Using a press, remove the No.1 hub sleeve assembly, 1st
gear and synchronizer ring.
(b) Remove the needle roller bearing, thrust washer and ball.
7. REMOVE NO.1 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO.1 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs
from the No.1 clutch hub.

MX07R-01
WM0064
WM0065
WM0066
MT0071
ABC MX-30
- MANUAL TRANSAXLEOUTPUT SHAFT
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.
3. INSPECT OUTPUT SHAFT
(a) Check the output shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Minimum outer diameter:
Part A: 32.970 mm (1.2980 in.)
Part B: 37.970 mm (1.4949 in.)
Part C: 31.970 mm (1.2587 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.

CM0015
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-31
1996 TERCEL (RM440U)
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 in.)
If the runout exceeds the maximum, replace the output shaft.