TOYOTA TERCEL 1996 Service Repair Manual

SA11J-05
SA-34
- SUSPENSION AND AXLEFRONT LOWER BALL JOINT
850 Author
: Date
:
1996 TERCEL (RM440U)
FRONT LOWER BALL JOINT
COMPONENTS

SA11K-01
SA3121
SST
- SUSPENSION AND AXLEFRONT LOWER BALL JOINT
SA-35
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE STEERING KNUCKLE WITH AXLE HUB
(See page SA-10)
2. REMOVE LOWER BALL JOINT
(a) Remove the clip and nut.
Torque: 98 N´m (1,000 kgf´cm, 72 ft´lbf)
(b) Using SST, remove the lower ball joint.
SST 09628-6201 1

SA11L-05
N00208
SA-36
- SUSPENSION AND AXLEFRONT LOWER BALL JOINT
1996 TERCEL (RM440U)
INSPECTION
INSPECT LOWER BALL JOINT FOR ROTATION CONDI-
TION
(a) As shown flip the ball joint stud back and forth 5 times, be-
fore installing the nut.
(b) Using a torque wrench, turn the nut continuously one turn
per 2 - 4 seconds and take the torque reading on the 5th
turn.
Turning torque:
0.78 - 2.45 N´m (8 - 25 kgf´cm, 7.0 - 22.0 in.´lbf)

BR0R8-01
- BRAKEBRAKE SYSTEM
BR-1
875 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE SYSTEM
PRECAUTION

Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts having the same part number
or equivalent.

It is very important to keep parts and the area clean when repairing the brake system.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.

BR0R9-06
BR-2
- BRAKETROUBLESHOOTING
876 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Lower pedal or spongy pedal
1. Brake system (Fluid leaks)
2. Brake system (Air in)
3. Piston seals (Worn or damaged)
4. Rear brake shoe clearance (Out of adjustment)
5. Master cylinder (Faulty)
6. Booster push rod (Out of adjustment)DI-145
BR-4
BR-23
BR-33
BR-9
BR-18
Brake drag
1. Brake pedal freeplay (Minimal)
2. Parking brake lever travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Rear brake shoe clearance (Out of adjustment)
5. Pad or lining (Cracked or distorted)
6. Piston (Stuck)
7. Piston (Frozen)
8. Anchor or return spring (Faulty)
9. Booster push rod (Out of adjustment)
10. Booster system (Vacuum leaks)
11. Master cylinder (Faulty)BR-6
BR-8
-
BR-33
BR-20
BR-29
BR-23
BR-23
BR-29
BR-16
BR-16
BR-9
Brake pull
1. Piston (Stuck)
2. Pad or lining (Oily)
3. Piston (Frozen)
4. Disc (Scored)
5. Pad or lining (Cracked or distorted)BR-23
BR-20
BR-29
BR-23
BR-23
BR-20
BR-29
Hard pedal but brake inefficient
1. Brake system (Fluid leaks)
2. Brake system (Air in)
3. Pad or lining (Worn)
4. Pad or lining (Cracked or distorted)
5. Rear brake shoe clearance (Out of adjustment)
6. Pad or lining (Oily)
7. Pad or lining (Glazed)
8. Disc (Scored)
9. Booster push rod (Out of adjustment)
10. Booster system (Vacuum leaks)DI-145
BR-4
BR-20
BR-29
BR-20
BR-29
BR-33
BR-20
BR-29
BR-20
BR-29
BR-23
BR-16
BR-9

- BRAKETROUBLESHOOTING
BR-3
877 Author
: Date
:
1996 TERCEL (RM440U)Symptom
Suspect AreaSee page
Noise from brake
1. Pad or lining (Cracked or distorted)
2. Installation bolt (Loosen)
3. Disc (Scored)
4. Pad support plate (Loosen)
5. Sliding pin (Worn)
6. Pad or lining (Dirty)
7. Pad or lining (Glazed)
8. Anchor or return spring (Faulty)
9. Anti-squeal shim (Damage)
10. Hold-down spring (Damage)BR-20
BR-29
BR-23
BR-23
BR-23
BR-23
BR-20
BR-29
BR-23
BR-29
BR-29
BR-20
BR-29

BR0RA-07
BR5038
BR5040
BR5039
BR3885
BR-4
- BRAKEBRAKE FLUID
878 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE FLUID
BLEEDING
HINT:
If any work is done on the brake system or air in the brake lines
is suspected, bleed the system of air.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Fluid: SAEJ1703 or FMVSS No.116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or the reservoir
becomes empty, bleed the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outer holes with your finger and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the air out of the
brake line for each wheel.

- BRAKEBRAKE FLUID
BR-5
879 Author
: Date
:
1996 TERCEL (RM440U)
4. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid: SAEJ1703 or FMVSS No.116 DOT3

R12354
Stop Light Switch
Push Rod
Pedal Height
BR4980
A
BR1DT-01
BR-6
- BRAKEBRAKE PEDAL
880 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE PEDAL
ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
EZ Grade:
143.0 - 153.0 mm (5.630 - 6.024 in.)
Except EZ Grade:
140.0 - 150.0 mm (5.512 - 5.906 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 - 2.4 mm (0.020 - 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check the stop lights come on when the brake pedal is de-
pressed, and go off when the brake pedal is released.
(l) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the brack ped-
al stopper has been adjusted correctly, the pedal freeplay will
meet the specifications.

R12355
Pedal Freeplay
BR4228
Pedal Reserve Distance
- BRAKEBRAKE PEDAL
BR-7
881 Author
: Date
:
1996 TERCEL (RM440U)
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance, as shown.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake.
(b) With the engine running, depress the pedal and measure
the pedal reserve distance.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf):
w/o ABS: More than 60 mm (2.36 in.)
w/ ABS: More than 55 mm (2.17 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.