1996 TOYOTA TERCEL Service Repair Manual

AX08L-03
Z16063
ACCIG
KLS
+E STP
Wire Harness Side
AT8748
AT8749
AX-24
- AUTOMATIC TRANSAXLE (A132L)SHIFT LOCK SYSTEM
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT SHIFT LOCK CONTROL ECU
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the ECU connector.
TerminalMeasuring ConditionVoltage (V)
ACC - EIgnition Switch ACC10 - 14
IG - EIgnition Switch ON10 - 14
STP - EDepress brake pedal10 - 14
KLS+
- E
1 Ignition switch ACC and P position
2 Ignition switch ACC and except P position
3 (After approx 1 second)0
10 - 14
6 - 9
2. INSPECT KEY INTERLOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between ter-
minals.
Standard resistance: 12.5 - 16.5 W
If resistance value is not as specified, replace the solenoid.
(c) Apply battery positive voltage between terminals. Check
that the solenoid can be heard operating.
If the solenoid does not operate, replace the solenoid.

AX08M-03
Q07634
RH Drive Shaft

Snap
RingSpeedometer
Cable
Rear Engine
Mounting InsulatorAir Cleaner
Assembly

Snap RingTie Rod End
LH Drive Shaft
Nut Cap Plug for Governor Pressure Test
Oxygen Sensor
Front Exhaust Pipe Torque Converter
Clutch
Clip
Control Cable

Gasket
Compression Spring
Engine Under Cover
Cotter Pin Starter

Gasket
Clamp x 6
Plug for Line
Pressure Test

Non-reusable partx 5
Converter
Cover
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE UNIT
AX-25
777 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

AX08N-03
Q06547
Q06548
Q07635
Q08079
AX-26
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE THROTTLE CABLE
4. REMOVE UPPER SIDE MOUNTING BOLTS
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
5. REMOVE STARTER
(a) Disconnect the cable and connector.
(b) Remove the starter with the 2 bolts.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
6. REMOVE GROUND CABLES AND BRACKET
7. INSTALL ENGINE SUPPORT FIXTURE
8. RAISE VEHICLE
9. REMOVE ENGINE UNDER COVER
10. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-18)
11. DISCONNECT SPEEDOMETER CABLE
12. DISCONNECT CONTROL CABLE
(a) Remove the clip from the control cable.
(b) Disconnect the control cable from the lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
13. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
14. DISCONNECT OIL COOLER HOSE FROM PIPE
15. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
Torque: 44 N´m (450 kgf´cm, 32 ft´lbf)
(b) Remove the bolts and springs from the exhaust manifold
and front exhaust pipe.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the clamp.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)

Q06735
Q06553
Q06554
Q08080
ABA
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE UNIT
AX-27
1996 TERCEL (RM440U)
(d) Remove the front exhaust pipe and gaskets.
HINT:
Replace the used gaskets with new ones.
16. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
(a) Remove the converter cover.
(b) Turn the crankshaft to gain access and remove the 6 bolts
with holding the crankshaft pulley set bolt with a wrench.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
17. SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
18. DISCONNECT LH ENGINE MOUNTING BRACKET
Remove the 2 mounting bolts.
Torque: 49 N´m (490 kgf´cm, 36 ft´lbf)
19. REMOVE ENGINE REAR MOUNTING
(a) Remove the rear mounting insulator through bolt.
Torque: 65 N´m (650 kgf´cm, 48 ft´lbf)
(b) Remove the 5 bolts and rear mounting insulator.
Torque:
Bolt A: 80 N´m (800 kgf´cm, 59 ft´lbf)
Bolt B: 92 N´m (920 kgf´cm, 69 ft´lbf)

Q06556
C
B
AD
B AX-28
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE UNIT
1996 TERCEL (RM440U)
20. REMOVE TRANSAXLE MOUNTING BOLT
Torque:
Bolt A: 7.4 N´m (75 kgf´cm, 65 in.´lbf)
Bolt B: 25 N´m (250 kgf´cm, 18 ft´lbf)
Bolt C: 46 N´m (470 kgf´cm, 34 ft´lbf)
Bolt D: 64 N´m (650 kgf´cm, 47 ft´lbf)

AT0943
AX08O-03
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE UNIT
AX-29
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL CHECK TORQUE CONVERTER
Using calipers and a straight edge, measure the distance from
the installed surface to the front surface of the transaxle hous-
ing.
Correct distance: More than 13.0 mm (0.512 in.)
2. INSTALL TRANSAXLE
Installation is in reverse order of removal.
HINT:

After installation, adjust the shift cable and park/newtral
position switch (See page AX-2).

Fill ATF and check fluid level (See page AX-2).

Test drive the vehicle.

AT0952
SST
AX0RT-01
AT0953
SST
AT3306
Hold
TurnLock
Free
AT2821
AT2820
AX-30
- AUTOMATIC TRANSAXLE (A132L)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
782 Author
: Date
:
1996 TERCEL (RM440U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE-WAY CLUTCH
(a) Install SST in the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
(c) With the torque converter clutch held upright, inspect the
clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch. Replace
the converter clutch if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification, replace the drive
plate. If installing a new drive plate, note the orientation of
spacers and tighten the bolts.
Torque: 88 N´m (900 kgf´cm, 65 ft´lbf)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator, measure the torque converter
clutch sleeve runout.
Maximum runout: 0.30 mm (0.0018 in.)
If the runout is not within the specification, try to correct by reori-
enting the installation of the converter.
HINT:
Mark the position of the converter clutch to ensure the correct
installation.

AX07W-05
D09118
PositionC1C2C3B1B2Shift Lever
GearShift
Solenoid
Valve No.1 No.2 One-Way Clutch (F
2)
1st and Reverse Brake (B
3)
U/D Brake (B
4)
U/D One-Way Clutch (F
3)
U/D Clutch (C3) Direct Clutch (C
2) 2nd Brake (B
2)
Forward Clutch (C1)
2nd Coast Brake (B
1)
Shift
Solenoid
Valve No.2B
4B3
Front Planetary Gear Unit
F
1F2F3
ON
OFF
ON
ON ON
ON OFF OFF
ON ON ON ON
ON ON OFF OFF ONOFF OFF
OFF OFF OFF
ON
ON





































































2nd Neutral ReversePark
1st
O/D3rd
2nd* 2nd 1st
3rd*
1st P
N
D
2
L

: Operating
*: Down-shift only in the 3rd gear for the 2 position and 2nd gear for the L position - no up-shiftRear
Planetary
Gear Unit
U/D Planetary Gear UnitNo.1 One-Way Clutch (F
1)
ROperating
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-1
783 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE SYSTEM (A242L)
OPERATION