Page 99 of 1202
PP3IZ-01
PP-52
- PREPARATIONSUSPENSION AND AXLE
99 Author: Date:
1996 TERCEL (RM440U)
SUSPENSION AND AXLE
SST (Special Service Tools)
09223-00010Cover & Seal ReplacerRear suspension
09223-15020Oil Seal & Bearing ReplacerFront axle
09308-00010Oil Seal PullerFront axle
Rear axle
09309-36010Transmission Rear Bearing
ReplacerFront drive shaft
09316-2001 1Transfer Bearing ReplacerFront drive shaft
09520-00031Rear Axle Shaft PullerFront axle
09550-10013Replacer Set ºBºRear axle
(09553-10010)Differential Side Bearing
Replacer
(09557-1001 1)Differential Drive Pinion
Front Bearing Replacer
09608-10010Steering Knuckle Oil Seal
ReplacerFront axle
09608-16042Front Hub Bearing Adjusting ToolFront drive shaft
(09608-02021)Bolt & Nut
Page 100 of 1202
- PREPARATIONSUSPENSION AND AXLE
PP-53
100 Author: Date:
1996 TERCEL (RM440U)
(09608-02041)Retainer
09628-1001 1Ball Joint PullerFront axle
09628-6201 1Ball Joint PullerFront axle
Front drive shaft
Front suspension
09631-12040Oil Seal ºAº ReplacerFront axle
09727-30021Coil Spring CompressorFront suspension
Rear suspension
09729-22031Front Spring Upper Seat HolderFront suspension
09751-3601 1Brake Line Union Nut 10 x 12 mm
WrenchBrake Line
09950-00020Bearing RemoverFront axle
Front drive shaft
09950-60010Replacer SetFront axle
Rear axle
(09951-00460)Replacer 46
(09951-00610)Replacer 61
(09951-00650)Replacer 65
09950-70010Handle SetFront axle
Rear axle
Page 150 of 1202
SS0NG-06
SS-20
- SERVICE SPECIFICATIONSSTARTING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
End cover x Brush holder1.51513 in.´lbf
End cover x Starter housing Planetary type
Reduction type5.9
9.360
9552 in.´lbf
82 in.´lbf
Magnetic switch x Starter housing Planetary type
Reduction type8.3
9.385
9573 in.´lbf
82 in.´lbf
Lead wire of field frame x Magnetic switch Planetary type
Reduction type9.8
5.9100
6087 in.´lbf
52 in.´lbf
Intake manifold x Intake manifold stay17.517513
Cylinder block x Intake manifold stay17.517513
Starter wire x Terminal 30 of starter8.89078 in.´lbf
Starter x Transaxle3737027
Terminal nut x Terminal C of starter1717312
Terminal nut x Terminal 30 of starter1717312
Magnetic switch end cover x Magnetic switch3.63632 in.´lbf
Page 157 of 1202

SS0KQ-04
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-27
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Engine 17 mm head
14 mm head
10 mm head64
46
7.4650
470
7547
34
65 in.´lbf
Engine left mounting bracket x Insulator4849036
Engine rear mounting insulator x Body7880058
Engine rear mounting insulator x Bracket B bolt
C bolt64
90650
92047
67
Front exhaust pipe clamp set bolt1919014
Front exhaust pipe x Exhaust manifold6263046
Starter x Transaxle3940029
Clutch release cylinder x Transaxle121209
Shift lever assembly x Body121209
Grommet retainer x Body4.95043 in.´lbf
Retainer x Body4.95043 in.´lbf
Output shaft front bearing lock plate set bolt1111 58
Transmission case x Transaxle case2930022
Reverse shift arm bracket1717513
Straight screw plug (Reverse restrict pin) (C151)
Straight screw plug13
13130
1309
9
Straight screw plug (Shift fork shaft)2525018
Straight screw plug (Lock ball assembly) (C151)
Straight screw plug (C141)39
39400
40029
29
Reverse idler gear shaft lock bolt2930022
Rear bearing retainer2728020
Output shaft lock nut11 81,20087
Shift fork and shift head x Shift fork shaft1616012
Shift and select lever assembly2020014
Transmission case x Transmission case cover1818513
Back-up light switch4041030
Filler and drain plugs3940029
Ring gear x Differential case1241,26091
Speedometer driven gear1111 58
Control lever housing support bracket x Transmission case1111 58
Selecting bellcrank assembly x Transmission case2525018
Shift and select lever shaft assembly lock bolt2930022
Transaxle case receiver x Transaxle case1111 58
No. 1 and No. 2 oil receiver pipe1717513
Page 159 of 1202

SS0LL-04
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A132L)
SS-29
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pan drain plug4950036
Oil pan4.95043 in.´lbf
Detent spring101007
Valve body x Oil pipe clamp101007
Valve body x Oil strainer101007
Valve body x Apply pipe bracket101007
Valve body x Transaxle101007
Park/neutral position switch x Transaxle case (bolt)5.45548 in.´lbf
Park/neutral position switch (nut)6.97061 in.´lbf
Transaxle control shaft lever x Park/neutral position switch131309
Transaxle control shaft lever x Transaxle control cable121209
Drive plate x Crankshaft8890065
Torque converter clutch x Drive plate2728020
Starter3940029
Transaxle housing x Engine (upper side)6465047
Transaxle housing x Engine (lower side) Bolt A
Bolt B
Bolt C
Bolt D7.4
25
46
6475
250
470
65065 in.´lbf
18
34
47
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Oxygen sensor4445032
Exhaust pipe clamp1919014
LH engine mounting x Body4949036
Engine rear mounting bracket x Engine rear mounting insulator6565048
Engine rear mounting insulator x Body Bolt A
Bolt B80
92800
92059
69
Page 161 of 1202

SS0LJ-04
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A242L)
SS-31
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pan drain plug1717513
Oil pan4.95043 in.´lbf
Detent spring101007
Valve body x Oil pipe clamp101007
Valve body x Oil strainer101007
Valve body x Apply pipe bracket101007
Valve body x Transaxle101007
Park/neutral position switch x Transaxle case (bolt)5.45548 in.´lbf
Park/neutral position switch (nut)6.97061 in.´lbf
Transaxle control shaft lever x Park/neutral position switch131309
Transaxle control shaft lever x Transaxle control cable121209
Drive plate x Crankshaft8890065
Torque converter clutch x Drive plate2728020
Starter3940029
Transaxle housing x Engine (upper side)6465047
Transaxle housing x Engine (lower side) Bolt A
Bolt B
Bolt C7.4
64
4675
650
47065 in.´lbf
47
34
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Oxygen sensor4445032
Exhaust pipe clamp1919014
LH engine mounting x Body4949036
Engine rear mounting bracket x Engine rear mounting insulator6565048
Engine rear mounting insulator x Body Bolt A
Bolt B80
92800
92059
69
Page 163 of 1202

SS0LP-06
- SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS-33
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT:
Disc brake dust cover x Steering knuckle8.38574 in.´lbf
Lower ball joint x Steering knuckle981,00072
Steering knuckle x Shock absorber2452,500181
Lower ball joint x Lower suspension arm8082059
Tie rod end lock nut4748035
Tie rod end x Steering knuckle4950036
Disc brake caliper x Steering knuckle8890065
Drive shaft lock nut2162,200159
Piston rod x Suspension support4747534
Suspension support x Body3940029
Flexible hose x Shock absorber2930022
Lower suspension arm x BodyFront side1421,450105Lower sus ension arm x Body Front side
Rear side
142
74
1,450
750
105
55
Hub nut1031,05076
ABS speed sensor x Steering knuckle7.88069 in.´lbf
REAR:
Piston rod x Suspension support3435025
Suspension support x Body3940029
Shock absorber x Axle beam6869050
Backing plate x Axle beam7071051
Parking brake cable x Backing plate7.88069 in.´lbf
Brake line x Wheel cylinder1515511
Body x Axle beam1421,450105
Lateral control rod x Axle beam8385061
Lateral control rod x Body11 31,15083
ABS speed sensor x Axle beam7.88069 in.´lbf
ABS speed sensor wire x Axle beam5.45548 in.´lbf
Page 165 of 1202
SS0M3-10
- SERVICE SPECIFICATIONSBRAKE
SS-35
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.´lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket1414510
Front disc brake caliper installation bolt2525518
Bleeding plug8.38574 in.´lbf
Front disc brake torque plate x Steering knuckle8890065
Front disc brake caliper x Flexible hose3031022
Rear drum brake wheel cylinder x Backing plate101007
ABS actuator assembly x Body1919514
ABS actuator x ABS actuator bracket assembly5.45548 in.´lbf
ABS actuator x ABS actuator No. 3 bracket1919514
Front speed sensor x Steering knuckle8.08271 in.´lbf
Front speed sensor wire harness clamp installation bolt5.05144 in.´lbf
Rear speed sensor x Axle beam8.08271 in.´lbf
Rear speed sensor wire harness clamp installation bolt5.05144 in.´lbf