boot TOYOTA TERCEL 1996 Service User Guide

CL05Y-01
CL0672
CL-12
- CLUTCHCLUTCH RELEASE CYLINDER
1996 TERCEL (RM440U)
REASSEMBLY
1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSTALL PISTON WITH SPRING INTO CYLINDER
3. INSTALL BOOT WITH PUSH ROD TO CYLINDER

CL060-03
Z14164
Flywheel
Clutch Disc
Clutch Cover
Boot Release Fork Release Bearing with Hub X6 CL-14
- CLUTCHCLUTCH UNIT
709 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH UNIT
COMPONENTS

MX07Z-04
Z18913
Clutch Release Bearing
Clutch Release Fork
Clutch Release Fork Boot
Clutch Release Fork Support
Oil Seal
Oil Seal
Transaxle Case
Oil Seal
Input Shaft Front Bearing
Output Shaft Cover
Output Shaft Front Bearing
Bearing Lock Plate
 Non-reusable partSpeedometer Driven Gear
Control Lever Housing
Support Bracket
Transaxle Case Receiver
Differential Case Assembly Outer Race Magnet
Plate Washer
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-7
719 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS

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

Z13623
RPMidle
AT5867Drain plug Filler plug
MT0613
Filler Hole
Fluid Level
0 - 5 mm
e
Z15674
Adjusting Nut
Outer Cable Rubber Boot
Cable Stopper0 - 1 mm
BE1485
8 423
5 761
9 AX-4
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
(4) Start the engine and shift the selector into all posi-
tions from the P position through the L position and
then shift it into the P position.
(5) With the engine idling, check the fluid level. Add the
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature 70 - 80 °C (158 - 176 °F) and add as nec-
essary.
NOTICE:
Do not overfill.
(d) If necessary, replace the differential fluid.
(1) Using a hexagon wrench, remove the drain plug
and drain the fluid.
(2) Using a hexagon wrench, install the drain plug se-
curely.
(3) Remove the filler plug.
(4) Add new fluid until it begins to run out of the filler
hole.
Fluid type: ATF D-ll or DEXRON®lll (DEXRON®ll)
Capacity: 1.4 liters (1.5 US qts, 1.2 lmp.qts)
(e) Check the differential fluid level.
Remove the filler plug and check the differential fluid lev-
el.
(f) Inspect and adjust the throttle cable.
(1) Depress the accelerator pedal all the way and
check that the throttle valve opens fully.
HINT:
If the throttle valve does not open fully, adjust the accelerator
link.
(2) Fully depress the accelerator.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and the stopper on the cable is
the standard.
Standard boot and cable stopper distance:
0 - 1 mm (0 - 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustment.
(g) Inspect the park/neutral position switch.
(1) Remove the park/neutral position switch
(See page AX-15).

Z15674
Adjusting Nut
Outer Cable Rubber Boot
Cable Stopper0 - 1 mm
Q06559
Q01095
AX-4
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U)
NOTICE:
Do not overfill.
(d) Inspect and adjust the throttle cable.
(1) Depress the accelerator pedal all the way and
check that the throttle valve opens fully.
HINT:
If the throttle valve does not open fully, adjust the accelerator
link.
(2) Fully depress the accelerator.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and the stopper on the cable is
the standard.
Standard boot and cable stopper distance:
0 - 1 mm (0 - 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustment.
(e) Adjust the shift control cable.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator correctly indicates the position.
(1) Remove the engine under cover.
(2) Loosen the nut on the control shaft lever.
(3) Push the control shaft lever fully toward the right
side of the vehicle.
(4) Return the lever 2 notches to the NEUTRAL posi-
tion.
(5) Set the shift lever to the N position.
(6) While holding the lever lightly toward the ºRº posi-
tion side, tighten the swivel nut.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(f) Adjust the park/neutral position switch.
If the engine will start with the shift selector in any position other
than the N or P position, adjustment is required.
(1) Loosen the park/neutral position switch bolts and
set the shift selector to the N position.
(2) Align the groove with neutral basic line.
(3) Hold the switch in the position and tighten the bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(g) Inspect the idle speed.
Idle speed:
750 ± 50 rpm (In the N position and A/C OFF)

F01195
Bolt
Adjusting
ValueSet Bolt
15'
30'Adjusting Bolt90105-15001 90105-15004 90105-15005 90105-15006
45'
1°00'
1°15'
1°30'121212121 Dot 2 Dots 3 Dots
W00533
W00533
SA-6
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
822 Author
: Date
:
1996 TERCEL (RM440U)
If the camber is not within the specification, using the table be-
low, estimate of how much additional camber adjustment will be
required, and select the camber adjusting bolt.
(i) Follow the above mentioned steps again. Between step
(b) and (c), exchange 1 or 2 selected bolts.
HINT:
When exchanging the 2 bolts, exchange 1 bolt for each time.
6. ADJUST TOE-IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right rack ends an equal amount to adjust
the toe-in.
Toe-in
(total)A + B: 0.1° ± 0.2°
C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
HINT:

Try to adjust the toe-in to the center value.

Make sure that the lengths of the left and right rack ends
are the same.
Tie rod end length difference: 1.5 mm (0.059 in.) or
less
(d) Torque the tie rod end lock nuts.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
(e) Place the boots on the seat and install the clamps to them.
HINT:
Make sure that the boots are not twisted.

SA128-02
FA1535
SST
F03986
SA-18
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
REMOVAL
NOTICE:

The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed. Therefore, if it is
absolutely necessary to place the vehicle weight on
the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)

w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the sensor rotor
serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. M/T:
REMOVE LH ENGINE UNDER COVER
3. DRAIN TRANSAXLE OIL (M/T) OR ATF (A/T)
4. w/ ABS:
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
5. REMOVE DRIVE SHAFT LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) While applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
6. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE (See page SA-10)
7. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See page SA-10)
8. DISCONNECT DRIVE SHAFT FROM AXLE HUB
NOTICE:
Be careful not to damage the drive shaft boot and inner oil
seal.

SA129-06
N00191
R11817
Matchmarks
N00194
Matchmarks
R09716
SST SA-20
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no play in the outboard joint.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no remarkable play in the radial
direction of the inboard joint.
2. REMOVE INBOARD JOINT TULIP
(a) Using a screwdriver, remove the 2 boot clamps.
(b) Place matchmarks on the inboard joint tulip and tripod.
(c) Remove the inboard joint tulip from the drive shaft.
3. REMOVE TRIPOD
(a) Using a snap ring expander, remove the snap ring.
(b) Place matchmarks on the shaft and tripod.
(c) Using a brass bar and hammer, remove the tripod joint
from the drive shaft.
4. REMOVE INBOARD JOINT BOOT AND 2 BOOT
CLAMPS
5. RH DRIVE SHAFT:
REMOVE DYNAMIC DAMPER
(a) Using a screwdriver, remove the damper clamp.
(b) Remove the damper from the drive shaft.
6. REMOVE OUTBOARD JOINT BOOT
(a) Using a screwdriver, remove the 2 boot clamps.
(b) Remove the boot and 2 boot clamp from the outboard
joint.
NOTICE:
Do not disassemble the outboard joint.
7. REMOVE DUST COVER
Using SST and a press, remove the dust cover from the inboard
joint tulip.
SST 09950-00020
8. w/o ABS:
REMOVE NO.2 DUST DEFLECTOR
(a) Mount the outboard joint in a soft jaw vise.
(b) Using a screwdriver, remove the No.2 dust deflector.

R11822
SST
SA12A-05
SA1459
R09694
Inboard Joint Boot Outboard Joint Boot
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA-21
1996 TERCEL (RM440U)
REASSEMBLY
1. w/o ABS:
INSTALL DUST DEFLECTOR NO.2
Using SST and a press, install a new dust deflector No.2.
SST 09309-36010, 09316-20011
2. INSTALL DUST COVER
Using a press, install a new dust cover to the inboard joint tulip.
3. TEMPORARILY INSTALL BOOTS, CLAMPS AND
DAMPER (RH DRIVE SHAFT)
HINT:
Before installing the boots, wrap vinyl tape around the spline of
the drive shaft to prevent damaging the boot.
(a) Temporarily install a new outboard joint boot.
(b) RH drive shaft:
Temporarily install the damper.
(c) Temporarily install a new inboard joint boot.
4. INSTALL TRIPOD
(a) Place the beveled side of the tripod axial spline toward the
outboard joint.
(b) Align the matchmarks before removal.
(c) Using a brass bar and hammer, tap in the tripod to the
drive joint shaft.
NOTICE:
Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
5. INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, pack the outboard joint and boot
with grease in the boot kit.
Grease capacity: 65 - 75 g (2.3 - 2.6 oz.)
6. INSTALL INBOARD JOINT TO FRONT DRIVE SHAFT
(a) Pack the inboard tulip and boot with grease in the boot kit.
Grease capacity: 112 - 122 g (4.0 - 4.3 oz.)
(b) Align the matchmarks as they were placed before disas-
sembly
(c) Install the inboard joint tulip to the drive shaft.
(d) Temporarily install the boot to the inboard joint shaft.