boot TOYOTA TERCEL 1996 Service Owner's Manual

Z12938
RH
LH
R09908
SA-22
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
7. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Make sure the boot are on the shaft groove.
(b) Set the drive shaft length to the standard.
Standard length
RH785.1 ± 5.0 mm (30.909 ± 0.197 in.)
LH544.9 ± 5.0 mm (21.421 ± 0.197 in.)
(c) Place the 4 new boot clamps to the boots.
(d) Bend the band, and lock it with a screwdriver.
8. RH DRIVE SHAFT:
ASSEMBLE DYNAMIC DAMPER CLAMP
(a) Be sure the damper is on the shaft groove.
(b) Set the distance, as shown.
Distance: 361.4 ± 5.0 mm (14.335 ± 0.197 in.)
(c) Place a new damper clamp to the damper.
(d) Bend the band and lock it in the same procedure for the
boot clamp assembly.
9. INSTALL SNAP RING
Using a snap ring expander, install a new snap ring to the in-
board joint shaft.
10. CHECK DRIVE SHAFT (See page SA-20)

BR0RR-03
N00747 BR3964 BR3965
BR3966
BR3968
BR3969
- BRAKEFRONT BRAKE CALIPER
BR-25
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE THESE PARTS:
(a) 2 sliding bushings.
(b) 4 dust boots.
2. REMOVE CYLINDER BOOT SET RING AND CYL-
INDER BOOT
Using a screwdriver, remove the cylinder boot set ring and cylin-
der boot from the caliper.
3. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
the caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
4. REMOVE PISTON SEAL
Using a screwdriver, remove the piston seal from the cylinder.

BR4387
BR3027
SST
BR0370
- BRAKEREAR DRUM BRAKE
BR-31
1996 TERCEL (RM440U)
(d) Using pliers, disconnect the parking brake cable from the
parking brake lever and remove the rear shoe.
6. REMOVE AUTOMATIC ADJUSTING LEVER AND
PARKING BRAKE LEVER
(a) Remove the E-ring.
(b) Remove the automatic adjusting lever.
(c) Remove the C-washer.
(d) Remove the parking brake lever.
7. REMOVE WHEEL CYLINDER
(a) Using SST, disconnect the brake line. Use a container to
catch the brake fluid.
SST 09751-3601 1
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
(b) Remove the 2 bolts and the wheel cylinder.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
8. DISASSEMBLE WHEEL CYLINDER
Remove the these parts from the wheel cylinder.

2 boots

2 pistons

2 piston cups

Spring

Z19009
 Non-reusable part

Precoated part
Molybdenum disulfide lithium base grease Tie Rod End
Lock Nut
Rack End
 Claw Washer
Steering Rack Rack Housing  Bushing Clip
Clamp Rack Boot
Pinion Bearing Adjusting
Screw Lock Nut

Rack Guide Spring Cap

Rack Guide Spring
Cap Lock Nut
Rack Guide Rack Guide Spring  Oil Seal

Pinion Bearing Adjusting Screw
 Bearing
Steering Pinion
 Bearing
Clamp
Rack Boot
Clip
 Claw Washer
Rack End
Lock Nut
Tie Rod End
- STEERINGMANUAL STEERING GEAR
SR-35
955 Author
: Date
:
1996 TERCEL (RM440U)

SR0KT-01
N00249
SST
N00250
Matchmarks
N00251
R12034
SST
R12035
SST
- STEERINGMANUAL STEERING GEAR
SR-37
1996 TERCEL (RM440U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE MANUAL STEERING GEAR IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612-00012
2. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS
Place matchmarks on the tie rod end and rack end.
3. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Remove the clamp screw from the boot.
NOTICE:

Be careful not to damage the boot.

Mark the RH and LH boots.
4. REMOVE RH AND LH RACK ENDS AND CLAW
WASHERS
(a) Using a screwdriver and hammer, unstake the washer.
NOTICE:
Avoid any impact on the steering rack.
(b) Using a spanner, hold the steering rack steadily and using
SST, remove the rack end.
SST 09922-10010
NOTICE:

Use SST 09922-10010 in the direction shown in the il-
lustration.

Mark the RH and LH rack ends.
5. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
6. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE
SPRING AND RACK GUIDE
Using a hexagon wrench (19 mm), remove the cap.

SR4254
N00345
R14426
SST
Oil Seal
W04041
SST
5 mm
Oil Seal SR-40
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
4. IF NECESSARY, REPLACE BUSHING
(a) Using a screwdriver, depress the projections on the bush-
ing to release the bushing, then remove the bushing from
the rack housing.
(b) Ensure that the hole of the rack housing is not clogged
with grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.
(c) Coat inside a new bushing with molybdenum disulfide lith-
ium base grease.
(d) Install the bushing into the rack housing, making sure to
align into the 3 holes.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, press out the oil seal from the pinion bearing
adjusting screw.
SST 09950-60010 (09951-00240),
09950-70010 (09951-07100)
(b) Coat a new oil seal lip with molybdenum disulfide lithium
base grease.
(c) Using SST, press in the oil seal with it is protruding 5 mm
(0.21 in.).
SST 09950-60010 (09951-00240),
09950-70010 (09951-07100)
NOTICE:
Make sure to install the oil seal facing the correct direction.

R12040
SST
Fulcrum
Length
N00349
R15520
0 mm
6 mm
(0.24 in.)
R15519
SR-44
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
10. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
(b) Using a spanner, hold the steering rack steadily and using
SST, torque the rack end.
SST 09922-10010
Torque: 43 N´m (434 kgf´cm, 31 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Using a brass bar and hammer, stake the washer.
NOTICE:
Avoid any impact on the rack.
11. INSTALL RH AND LH BOOTS, CLAMPS AND CLIPS
(a) Install the rack boot.
NOTICE:
Be careful not to damage or twist the boot.
(b) Install the clamp screw, as shown in the illustration.
(c) Install the clip.
HINT:
Face the open ends of the clips outward/upward as shown in
the illustration, to avoid damage to the boot.
12. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe-in, torque the nut.
(See page SA-4)
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)

SR17W-02
R11026
SST
R11027
SST
R13122
R11029
SST SR-50
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612-00012
2. REMOVE 2 TURN PRESSURE TUBES
(a) Using SST, remove the tube.
SST 09633-00020
(b) Remove the 2 union seats from the rack housing.
3. REMOVE AIR CONTROL VALVE
4. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS (See page SR-37)
5. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Using a screwdriver, loosen the clamp.
NOTICE:

Be careful not to damage the boot.

Mark the RH and LH boots.
6. REMOVE RH AND LH RACK ENDS AND CLAW WASH-
ERS (See page SR-37)
7. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
8. REMOVE RACK GUIDE SPRING CAP
Using a hexagon wrench (21 mm), remove the cap.
9. REMOVE RACK GUIDE SPRING, RACK GUIDE AND
RACK GUIDE SEAT
Remove the seat from the guide.
10. REMOVE RACK HOUSING CAP

R07337
Rack Groove
R11031
SST
Fulcrum
Length
R10934
Brass
Bar
F05319
SR4273
0 - 3 mm
(0 - 0.12 in.) SR-60
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
15. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
(b) Using a spanner, hold the steering rack steadily and using
SST, torque the rack end.
SST 09922-10010
Torque: 51 N´m (520 kgf´cm, 18 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Using a brass bar and a hammer, stake the washer.
NOTICE:
Avoid any impact on the rack.
16. INSTALL RH AND LH RACK BOOTS, CLAMPS AND
CLIPS
(a) Ensure that the steering rack hole is not clogged with
grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.
(b) Install the boot.
NOTICE:
Be careful not to damage or twist the boots.
(c) Tighten a new clamp, as shown in the illustration.