light TOYOTA TERCEL 1996 Service Repair Manual

Q06552
Q08461
AB
C
CC
A
Q06446
Q08159
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
MX-5
1996 TERCEL (RM440U)
14. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
(b) Remove the 2 bolts, springs and gasket.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the bolt, clamp and gasket.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(d) Disconnect the 2 rings and remove the exhaust front pipe.
15. REMOVE STARTER
Disconnect the connector and wire and remove the starter.
16. DISCONNECT SPEEDOMETER CABLE
17. REMOVE ENGINE REAR MOUNTING INSULATOR
Remove the 6 bolts and insulator.
Torque:
Bolt A: 78 N´m (800 kgf´cm, 58 ft´lbf)
Bolt B: 64 N´m (650 kgf´cm, 47 ft´lbf)
Bolt C: 90 N´m (920 kgf´cm, 67 ft´lbf)
18. DISCONNECT ENGINE LEFT MOUNTING BRACKET
FROM ENGINE LEFT MOUNTING INSULATOR
Remove the 2 bolts.
Torque: 48 N´m (490 kgf´cm, 36 ft´lbf)
19. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
20. REMOVE TRANSAXLE LOWER SIDE MOUNTING
BOLT
Remove the 4 bolts.
Torque:
14 mm head: 46 N´m (470 kgf´cm, 34 ft´lbf)
10 mm head: 7.4 N´m (75 kgf´cm, 65 in.´lbf)
21. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:

Align the input shaft with the clutch disc and install the
transaxle to the engine.

Install and torque the 7 bolts.
Torque:
Upper side mounting bolts: (See step 7)
Lower side mounting bolts: (See step 20)

Z18912
Oil Receiver Pipe
Straight Screw Plug (C141)


Slotted Spring Pin (C151)
Outer Race
Plate Washer Reverse Restrict Pin (C151)
Oil Receiver Pipe
x13 Transmission Case
 Lock Ball Assembly (C151)


Back-Up Light Switch
Lock Bolt
Breather Plug
Shift and Select Lever
Shaft Assembly
Selecting Bellcrank Assembly
Oil Seal
x9
Transmission Case
Cover (C141) Drain Plug
 Non-reusable part

Precoated partTransmission Case
Cover (C151)
x9
Gasket Gasket
Filler Plug


Straight Screw Plug
Straight Screw Plug (C141)
Gasket MX-8
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
720 Author
: Date
:
1996 TERCEL (RM440U)

MX0B1-02
Q07828
FIPG
N00038
N00039
MX-10
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE RELEASE FORK AND BEARING
HINT:
Apply molybdenum disulphide lithium base grease
(See page CL-17).
2. REMOVE SPEEDOMETER DRIVEN GEAR
Remove the driven gear lock plate set bolt and driven gear.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
3. REMOVE BACK-UP LIGHT SWITCH
Torque: 40 N´m (410 kgf´cm, 30 ft´lbf)
4. REMOVE CONTROL LEVER HOUSING SUPPORT
BRACKET
Remove the 3 bolts and bracket.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
5. REMOVE SELECTING BELLCRANK ASSEMBLY
Remove the 2 bolts and selecting bellcrank assembly.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
6. REMOVE TRANSMISSION CASE COVER
(a) Remove the 9 bolts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
(b) Carefully tap the projection of the transmission case cov-
er with a brass bar and hammer and remove the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent
7. C151:
INSPECT 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 - 0.57 mm (0.0039 - 0.0224 in.)
Maximum clearance: 0.65 mm (0.0256 in.)
8. C151:
INSPECT 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.
Standard clearance:
0.015 - 0.058 mm (0.0006 - 0.0023 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.

WM0064
MX07J-03
WM0065
WM0066
N00053
SST MX-16
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
INSPECTION
1. C151:
INSPECT 5TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine
lapping compound between the synchronizer ring and gear
cone.
(c) Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(d) Check again the braking effect of the synchronizer ring.
(e) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. C151:
INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
3. REMOVE TRANSAXLE CASE RECEIVER
Remove the bolt and transaxle case receiver.
4. IF NECESSARY, REPLACE INPUT SHAFT FRONT
BEARING AND OIL SEAL
(a) Using SST, remove the bearing.
SST 09612-65014

MX07N-01
WM0064
WM0065
WM0066
- MANUAL TRANSAXLEINPUT SHAFT
MX-23
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine
lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.

MX07R-01
WM0064
WM0065
WM0066
MT0071
ABC MX-30
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine
lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
3. INSPECT OUTPUT SHAFT
(a) Check the output shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Minimum outer diameter:
Part A: 32.970 mm (1.2980 in.)
Part B: 37.970 mm (1.4949 in.)
Part C: 31.970 mm (1.2587 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.

AT8103
Neutral Basic Line
Groove
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-5
1996 TERCEL (RM440U)
(2) Using an ohmmeter, check continuity between each
terminal shown below when the shift lever is put in
each position.
(h) Adjust the shift control cable.
(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.
(i) 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)
(j) Inspect the idle speed.
Idle speed:
750 ± 50 rpm (In the N position and A/C OFF)
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 fluid temperature 50 - 80°C (122 - 176 °F).
Do not continuously run this test longer than 5 seconds.
(1) Check the front and rear wheels.
(2) Connect the tachometer to the engine.
(3) Fully apply the parking brake.

AX-8
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
EVALUATION
ProblemPossible cause
If governor pressure defect.
 Line pressure defect
 Fluid leakage in governor pressure circuit
 Governor valve operation defect
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)186 - 365 kPa (1.9 - 2.7 kgf/cm2, 27 - 38 psi)
90 km/h (56 mph)353 - 431 kPa (3.6 - 4.4 kgf/cm2, 51 - 63 psi)
6. ROAD TEST
NOTICE:
Do this test at normal fluid temperature 50 - 80 °C (122 - 176 °F).
(a) D position test.
Shift into the D position and while driving with the accelerator pedal held constant at the throttle valve
fully open, check on the following points:
(1) Check to seethat the 1"2 and 2"3 up-shifts take placeand also that the shift points conform
to those shown in the automatic shift schedule (See page SS-28).
EVALUATION
ProblemPossible cause
If there is no 1 - 2 up-shift. Governor valve is defective
 1 - 2 shift valve is stuck
If there is no 2 - 3 up-shift. 1 - 2 shift valve is stuck
If the shift point is defective.Throttle cable out of adjustment
 Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, etc. are defective
(2) In the same way, check the shock and slip at 1 " 2 and 2 " 3 up-shifts.
EVALUATION
ProblemPossible cause
If the shock is severe.
 Line pressure is too high
 Accumulator is defective
 Check ball is defective
(3) Run in the 3rd gear of the D position, check the abnormal noise and vibration.
HINT:
Check for the cause of abnormal noise and vibration must be made with extreme care as they could also
be due to imbalance in the drive shaft, differential, tires and torque converter clutch, etc.
(4) While running in the 3rd gear of the D position, check that the possible kick-down vehicle speed
limits for the 3 " 1 and 3 " 2 kick-down conform to those indicated in the automatic shift sched-
ule (See page SS-28).
EVALUATION
ProblemPossible cause
If the possible kick-down vehicle speed limit is defective. Throttle cable out of adjustment
 Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, etc. are defective
(5) Check the abnormal shock and slip at kick-down.
(6) While running at about 60 km/h (37 mph) in the 3rd gear of the D position, release your foot from
the accelerator pedal and shift into the L position. Then check if the 2 "1 down-shift point con-
forms to that indicated in the automatic shift schedule (See page SS-28).
(b) Inspect the lock-up mechanism.
(1) Drive in the D position at a steady speed (Lock-up ON) of about 65 km/h (40 mph).
(2) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly.

Q06544
N00513
N00515
0.8 - 1.5 mm
200 mm
AX0RL-01
- AUTOMATIC TRANSAXLE (A132L)THROTTLE CABLE
AX-15
767 Author
: Date
:
1996 TERCEL (RM440U)
THROTTLE CABLE
ON-VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM ENGINE
Disconnect the cable from the throttle linkage.
2. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Disconnect the transaxle control cable from the transaxle
control shaft lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(b) Remove the nut and transaxle control shaft lever.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(c) Using a screwdriver, pry off the nut stopper.
(d) Remove the nut and nut stopper.
Torque: 6.9 N´m (70 kgf´cm, 61 in.´lbf)
(e) Remove the 2 bolts and park/neutral position switch.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
3. REMOVE VALVE BODY (See page AX-12)
4. REMOVE THROTTLE CABLE
(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.
HINT:
New cables does not habe a cable stopper staked.
(c) Bend the cable so that there is a radius of about 200 mm
(7.87 in.).
(d) Pull the inner cable lightly nutil a slight resistance is felt,
and hold it there.
(e) Stake the stoppe, 0.8-1.5 mm (0.031-0.059 in.) from the
end of outer cable.

AX08K-01
D01644
Stop Light SwitchKey Interlock Solenoid
Shift Lock
Override Button
Shift Lock Control
Unit Assembly
BatteryMAIN
FLALTStopIgnition Switch
ACC
IGCIG
ECU-IG
Stop Light
Switch
Stop
LightSTPShift Lock
Control ECUIG ACC
Key Interlock Solenoid
KLS
+
E WIRING DIAGRAM
- AUTOMATIC TRANSAXLE (A132L)SHIFT LOCK SYSTEM
AX-23
775 Author
: Date
:
1996 TERCEL (RM440U)
SHIFT LOCK SYSTEM
LOCATION