1996 TOYOTA TERCEL clutch removal

CL05R-01
Q06660
SST
- CLUTCHCLUTCH MASTER CYLINDER
CL-5
1996 TERCEL (RM440U)
REMOVAL
1. DRAW OUT FLUID WITH SYRINGE
2. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
3. REMOVE CLIP AND CLEVIS PIN
4. REMOVE 2 MOUNTING NUTS AND PULL OUT MAS-
TER CYLINDER
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)

CL05U-03
CL-8
- CLUTCHCLUTCH MASTER CYLINDER
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CL-5).
HINT:
After installation, bleed system and adjust clutch pedal.

CL05W-01
Q06706SST CL-10
- CLUTCHCLUTCH RELEASE CYLINDER
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-
INDER
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)

CL05Z-03
- CLUTCHCLUTCH RELEASE CYLINDER
CL-13
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CL-10).
HINT:
After installation, bleed clutch system.

CL061-01
CL0288Matchmarks
N00413
- CLUTCHCLUTCH UNIT
CL-15
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE TRANSAXLE FROM ENGINE
(See page MX-4)
2. REMOVE CLUTCH COVER AND DISC
(a) Place matchmarks on the flywheel and clutch cover.
(b) Loosen each set bolt one turn at a time until spring tension
is released.
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.
3. REMOVE RELEASE BEARING AND FORK FROM
TRANSAXLE
Remove the release bearing together with the fork and then
separate them.

MX07F-04
Q06439
Z1891017 mm Head
Starter Set Bolt
Q06443
Q09187
Filler Plug
Oil Level
0 - 5 mm
Drain Plug MX-4
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY AND AIR CLEANER CASE AS-
SEMBLY WITH AIR HOSE
2. REMOVE CLUTCH RELEASE CYLINDER AND LINE
CLAMP
(a) Remove the 2 bolts and release cylinder.
(b) Remove the 2 bolts and release cylinder line clamp.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
3. DISCONNECT GROUND CABLE
Remove the 2 bolts and disconnect the 2 ground cables from
the transaxle side and engine left mounting bracket side.
4. DISCONNECT BACK-UP LIGHT SWITCH CONNEC-
TOR
5. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
6. REMOVE STARTER SET BOLT
Remove the 2 set bolts of the starter from the transaxle upper
side.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
7. REMOVE TRANSAXLE MOUNTING BOLT
Remove the 3 bolts of transaxle case upper side.
Torque:
17 mm head: 64 N´m (650 kgf´cm, 47 ft´lbf)
8. INSTALL ENGINE SUPPORT FIXTURE
9. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
10. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
11. REMOVE LH AND RH ENGINE UNDER COVERS
12. DRAIN TRANSAXLE OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts)
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
13. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-17)

AX088-04
AT0943
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
AX-33
1996 TERCEL (RM440U)
INSTALLATION
1. TORQUE CONVERTER CLUTCH
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. TRANSAXLE INSTALLATION
Installation is in the reverse order of removal.
HINT:

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

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

Test drive the vehicle.

AC3IP-01
AC-38
- AIR CONDITIONINGCOMPRESSOR
1996 TERCEL (RM440U)
REMOVAL
1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
5. REMOVE ENGINE UNDER COVER
6. DISCONNECT CONNECTOR FROM MAGNETIC CLUTCH
7. DISCONNECT 2 HOSES FROM COMPRESSOR SERVICE VALVE
NOTICE:
Cap the open fitting immediately to keep moisture or dirt out of the system
8. REMOVE COMPRESSOR
(a) Loosen the compressor drive belt.
(b) Remove the compressor mounting bolts and the compressor.