TOYOTA TERCEL 1996 Service Repair Manual

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

AX0RV-02
(b) Check the idle speed.
(e) Check the shift linkage. (d) Check the throttle cable mark.
(f) Check the park/neutral position switch.
Check the engine and the torque converter clutch. (c) Check the fluid level and fluid condition.
STALL TEST
TIME LAG TEST PRELIMINARY CHECK
ROAD TEST HYDRAULIC TEST
MATRIC CHART (a) Check the tire inflation.
Measure the line pressure and make a basic check of fluid circuit.
Check if trouble lies within automatic transaxle. If noise or vibration occurs, the possible cause could
be with the compressor, engine, and drive shaft tires, etc. Check the automatic transaxle (each clutch, brake and gear) for wear.
(See page AX-13) AX-2
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U)
TROUBLESHOOTING
1. GENERAL INFORMATION
(a) Troubles occurring with the automatic transaxle can be caused by either the engine or the transaxle
itself. These 2 areas should be checked before proceeding with troubleshooting.
(b) Troubleshooting should begin with the simplest operation, working up in order of difficulty degree but
first determine whether the trouble lies within the engine or the transaxle.
(c) Proceed with the inspection as follows:

Q02129
AT3417
OK if hot
Add if hot
OR0028
Z13623
RPMidle
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-3
1996 TERCEL (RM440U)
2. PRELIMINARY CHECK
(a) Check the fluid level.
HINT:
The vehicle must have been driver so that the engine and trans-
axle are at normal operating.
ATF temperature: 70 - 80 °C (158 - 176 °F)
(1) Park the vehicle on the level surface and set the
parking brake.
(2) With the engine idling, shift the selector into each
gear from the P position to the L position and return
to the P position.
(3) Pull out the transaxle dipstick and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range. If the level is at the low side of the hot range,
add new fluid.
Fluid type: ATF DEXRON®ll
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the ATF.
NOTICE:
Do not overfill.
(1) Remove the drain plug and drain the fluid.
(2) Install the drain plug securely.
(3) Add new fluid through the filler pipe.
Fluid type: ATF DEXRON®ll
Dry fill: 7.2 liters (7.6 US qts, 6.3 lmp.qts)
Drain and refill: 3.1 liters (3.3 US qts, 2.7 lmp.qts)
(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.

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)

- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-5
1996 TERCEL (RM440U)
3. MEASURE STALL TEST
The object of this test is to check the overall performance of the transaxle and the engine by measuring the
maximum engine speeds in the D and R positions.
NOTICE:

Do the test at normal operating ATF temperature 50 - 80 °C (122 - 176 °F).

Do not continuously run this test longer than 5 seconds.
(1) Chock the 4 wheels.
(2) Fully apply the parking brake.
(3) Connect the tachometer to the engine.
(4) Start the engine and check the idle speed.
(5) Keep your left foot pressing firmly on the brake pedal.
(6) Shift it into the D position. Press all the way down on the accelerator pedal. Quickly read the stall
speed RPM at this time.
Stall speed: 2,300 ± 200 rpm
(7) Do the same test in the R position.
Stall speed: 2,300 ± 200 rpm
EVALUATION
ProblemPossible cause
(a) Stall speed low in D and R positions.
Engine output may be insufficient

Stator one-way clutch is not operating properly
(b) Stall speed high in D position.

Line pressure too low

Forward clutch slipping

No.2 one-way clutch not operating properly

U/D one-way clutch not operating properly
(c) Stall speed high in R position.

Line pressure too low

Direct clutch slipping

1st and reverse brake slipping

U/D brake slipping
(d) Stall speed high in D and R positions.

Line pressure too low

Improper fluid level

U/D brake slipping
4. MEASURE TIME LAG TEST
When the shift lever is shifted while the engine is idling, there will be a certain lapse of time or lag before
the shock can be felt. This is used for checking the condition of the U/D direct clutch, forward clutch, direct
clutch and 1st and reverse brake.
NOTICE:

Do the test at normal operating ATF temperature 50 - 80 °C (122 - 176°F).

Make sure to allow 1 minute interval between the tests.

Take three measurements and take the average value.
(1) Fully apply the parking brake.
(2) Start the engine and check the idle speed.
Idling speed: 750 ± 50 rpm (In N position and A/C OFF)
(3) Shift the shift lever from the N to D position. Using a stop watch, measure the time it takes from
shifting the lever to the shock is felt.
Time lag: Less than 1.2 seconds
(4) In the same way, measure the time lag for N " R.
Time lag: Less than 1.5 seconds

AX-6
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U)
EVALUATION (If N " D or N " R time lag is longer than the specified):
ProblemPossible cause
N " D time lag is longer
Line pressure too low

Forward clutch worn
N " R time lag is longer

Line pressure too low

Direct clutch worn

1st and reverse brake worn
5. HYDRAULIC TEST
(a) Measure the line pressure.
(1) Warm up the ATF.
(2) Remove the transaxle case test plug and mount SST (See page AX-29).
SST 09992-00094 (09992-00150, 09992-00270)
NOTICE:

Do the test at normal operating ATF temperature 50 - 80°C (122 - 176 °F).

The line pressure test should always be carried out in pairs. One should observe the conditions
of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(3) Chock the 4 wheels.
(4) Fully apply the parking brake.
(5) Start the engine and check the idle speed.
(6) Keep your left foot pressing firmly on the brake pedal and shift into the D position.
(7) Measure the line pressure when the engine is idling.
(8) Fully depress the accelerator pedal. Quickly read the highest line pressure when the engine
speed reaches the stall speed.
NOTICE:
Release the accelerator pedal and stop the test if the wheels begin to rotate before the engine speed
reaches the specified stall speed.
(9) In the same way, do the test in the R position.
Specified line pressure:
D positionIdling
Stall373 - 422 kPa (3.8 - 4.3 kgf/cm2, 54 - 61 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
R position Idling
Stall549 - 706 kPa (5.6 - 7.2 kgf/cm2, 80 - 102 psi)
1,638 - 1,902 kPa (16.7 - 19.4 kgf/cm2, 238 - 276 psi)
(10) If the measured pressures are not up to specified values, recheck the throttle cable adjustment
and retest it.

- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-7
1996 TERCEL (RM440U)
EVALUATION
ProblemPossible cause
If the measured values at all positions are higher.

Throttle cable out of adjustment

Throttle valve defective

Regulator valve defective
If the measured values at all positions are lower.

Throttle cable out of adjustment

Throttle valve defective

Regulator valve defective

Oil pump defective

U/D one-way clutch not operating properly
If pressure is low in the D position only.

D position circuit fluid leakage

Forward clutch defective

U/D one-way clutch not operating properly
If pressure is low in the R position only.

R position circuit fluid leakage

Direct clutch defective

1st and reverse brake defective

U/D one-way clutch not operating properly
(b) Measure the governor pressure.
(1) Warm up the ATF.
(2) Remove the transaxle case test plug and mount SST (See page AX-29).
SST 09992-00094 (09992-00111, 09992-00270)
NOTICE:

Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176 °F).

Check that the throttle cable is adjusted within the specifications.

Check that the tire pressures are adjusted according to the specifications.
(3) Check the parking brake to see that it is not applied.
(4) Start the engine.
(5) Shift into the D position and measure the governor pressures at the speeds specified in the table.
EVALUATION
ProblemPossible cause
If governor pressure is defective.

Line pressure defective

Fluid leakage in governor pressure circuit

Governor valve operation defective
Vehicle speed (Reference)Governor pressure
30 km/h (19 mph)59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
60 km/h (37 mph)196 - 275 kPa (2.0 - 2.8 kgf/cm2, 28 - 40 psi)
90 km/h (56 mph)363 - 441 kPa (3.7 - 4.5 kgf/cm2, 53 - 64 psi)
6. ROAD TEST
NOTICE:
Do this test at normal operating ATF temperature 50 - 80 °C (122 - 176 °F).
(a) D position test.
Shift into the D position and while driving with the accelerator pedal held constantly at the throttle valve
fully open, check on the following points:
(1) 1 " 2, 2 " 3 and 3 "O/D up-shifts should take place, and shift points should conform to those
shown in the automatic shift schedule (See page SS-30).