1996 TOYOTA TERCEL Service Repair Manual

MX07S-03
CM0009
Engine Side
N00077
N00078
N00079
MX-32
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the No.1 clutch hub and shifting keys to the No.1
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 BALL, THRUST WASHER, 1ST GEAR,
NEEDLE ROLLER BEARING, SYNCHRONIZER RING
AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT
SHAFT
(a) Install the ball to the shaft.
(b) Fit the thrust washer groove securely over the locking ball
when installing the thrust on the shaft.
(c) Apply gear oil to the needle roller bearing.
(d) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(e) Using a press, install the 1st gear and No.1 hub sleeve.

N00080
N00083
N00084
N00086
SST
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-33
1996 TERCEL (RM440U)
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.50 (0.0984)D2.68 (0.1055)
B2.56 (0.1008)E2.74 (0.1079)
C2.62 (0.1031)F2.80 (0.1102)
(b) Using a screwdriver and hammer, install the snap ring.
4. INSPECT 1ST GEAR THRUST CLEARANCE
(See page MX-28)
5. INSTALL SYNCHRONIZER RING, 2ND GEAR,
NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR
(a) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(b) Apply gear oil to the needle roller bearing.
(c) Install the 2nd gear.
(d) Using a press, install the 3rd driven gear.
6. INSPECT 2ND GEAR THRUST CLEARANCE
(See page MX-28)
7. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN
GEAR AND REAR BALL BEARING
(a) Install the output gear spacer.
(b) Using SST and a press, install the 4th driven gear and
rear ball bearing.
SST 09608-00071

MX07T-01
Q05961
Boot
Shift and Select Lever
Shaft
Control Shaft Cover
Snap Ring
Oil Seal

Gasket
Spring
No.2 Select Spring
Seat
Spring
E-Ring

Non-reusable part
Apply MP greaseSlotted Spring PinNo.1 Shift Inner LeverSlotted Spring Pin No.1 Select Spring Seat
No.2 Shift Inner LeverSelect Inner Lever
Shift Interlock
Plate
MX-34
- MANUAL TRANSAXLESHIFT AND SELECT LEVER SHAFT
746 Author
: Date
:
1996 TERCEL (RM440U)
SHIFT AND SELECT LEVER SHAFT
COMPONENTS

MX07U-03
Q06511

Oil Seal
Plate Washer

Outer Race and Side Bearing
Speedometer Drive Gear
Straight Pin

Side Bearing and Outer Race

Oil Seal
Ring Gear Plate Washer Differential Case Pinion Shaft
Pinion Gear
Thrust Washer
Side Gear
Thrust Washer

Non-reusable partx6
- MANUAL TRANSAXLEDIFFERENTIAL CASE
MX-35
747 Author
: Date
:
1996 TERCEL (RM440U)
DIFFERENTIAL CASE
COMPONENTS

MX07V-03
Z16129
SST
MT0081
Matchmarks
MT0083
MT0084
N00098
SST MX-36
- MANUAL TRANSAXLEDIFFERENTIAL CASE
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
(a) Using SST, remove the bearings from both sides of the
case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00360)
(b) Remove the speedometer drive gear from the RH side.
2. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and case.
(b) Remove the 6 bolts.
(c) Using a plastic hammer, remove the ring gear from the
case.
3. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear
while holding one pinion toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specification, install the correct
thrust washer to the side gears.
4. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, remove the pinion shaft
straight pin.
(b) Remove the pinion shaft from the case.
(c) Remove the 2 pinion gears and side gears with the 4
thrust washers from each gear.
5. Transmission Case Side:
IF NECESSARY, REPLACE OIL SEAL AND SIDE
BEARING OUTER RACE
(a) Using a screwdriver and hammer, remove the oil seal.
(b) Using SST, remove the outer race and plate washer.
SST 09612-65014
(c) Place the plate washer into the case.

Q08120
SST
Q08121
SST 2.4 ± 0.3 mm
N00100
SST
Z16127
SST
Q06517
SST 1.9 ± 0.3 mm
- MANUAL TRANSAXLEDIFFERENTIAL CASE
MX-37
1996 TERCEL (RM440U)
(d) Using SST and a hammer, install a new outer race.
SST 09950- 60020 (09951- 00710), 09950- 70010
(09951-07150)
(e) Using SST and a hammer, install a new oil seal.
SST 09350-32014 (09351-32111, 09351-32130)
Drive in depth: 2.4 ± 0.3 mm (0.094 ± 0.012 in.)
(f) Coat the lip of the oil seal with MP grease.
6. Transaxle Case Side:
IF NECESSARY, REPLACE OIL SEAL AND SIDE
BEARING OUTER RACE
(a) Using a screwdriver and hammer, remove the oil seal.
(b) Using SST, remove the outer race and plate washer.
SST 09612-65014
(c) Place the plate washer into the case.
(d) Using SST and a hammer, install a new outer race.
SST 09950- 60020 (09951- 00680), 09950- 70010
(09951-07150)
(e) Using SST and a hammer, install a new oil seal.
SST 09350-32014 (09351-32130, 09351-32150)
Drive in depth: 1.9 ± 0.3 mm (0.075 ± 0.012 in.)
(f) Coat the lip of the oil seal with MP grease.

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)--