TOYOTA TERCEL 1996 Service Repair Manual

CL061-01
CL0288Matchmarks
N00413
- CLUTCHCLUTCH UNIT
CL-15
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE TRANSAXLE FROM ENGINE
(See page MX-4)
2. REMOVE CLUTCH COVER AND DISC
(a) Place matchmarks on the flywheel and clutch cover.
(b) Loosen each set bolt one turn at a time until spring tension
is released.
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.
3. REMOVE RELEASE BEARING AND FORK FROM
TRANSAXLE
Remove the release bearing together with the fork and then
separate them.

CL062-01
CL0239
CL0373
CL0290
Z08001
AB
N00414
CL-16
- CLUTCHCLUTCH UNIT
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 in.)
If necessary, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout: 0.8 mm (0.031 in.)
If necessary, replace the clutch disc.
3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 in.)
If necessary, replace the flywheel.
4. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum depth:
A: 0.6 mm (0.024 in.)
Maximum width:
B: 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
5. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If necessary, replace the release bearing.

CL063-03
Q06681
Flywheel Side
CL0291
1.4
MatchmarksSST 7 3
6
2.58
Q06392
SST
N00415
CL0653
- CLUTCHCLUTCH UNIT
CL-17
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them.
SST 09301-00210
(b) Align the matchmark on the clutch cover and flywheel.
(c) Torque the bolts on the clutch cover in the order shown.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
HINT:
Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333-00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to these parts:

Release fork and hub contact point

Release fork and push rod contact point

Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887-01706 (100 g).
4. INSTALL RELEASE BEARING AND FORK TO TRANS-
AXLE
Install the bearing to the release fork, and then install them to
the transaxle.
5. INSTALL TRANSAXLE TO ENGINE
(See page MX-6)

MX03N-01
- MANUAL TRANSAXLEMANUAL TRANSAXLE SYSTEM
MX-1
713 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE SYSTEM
PRECAUTION
When working with FIPG material, you must observe the following items.

Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-
faces.

Thoroughly clean all components to remove all the loose material.

Clean both sealing surfaces with a non-residue solvent.

Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.

Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.

MX07D-03
MX-2
- MANUAL TRANSAXLETROUBLESHOOTING
714 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
Noise
15.Oil (Level low)
16.Oil (Wrong)
17.Gear (Worn or damaged)
18.Bearing (Worn or damaged)MX-4
MX-4
MX-7
MX-7
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O-Ring (Worn or damaged)MX-4
MX-7
MX-7
MX-7
Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)MX-40
MX-20
MX-27
MX-20
MX-27
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX-7
MX-7
MX-7
MX-7

MX07E-04
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
MX-3
715 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE UNIT
COMPONENTS

MX07F-04
Q06439
Z1891017 mm Head
Starter Set Bolt
Q06443
Q09187
Filler Plug
Oil Level
0 - 5 mm
Drain Plug MX-4
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY AND AIR CLEANER CASE AS-
SEMBLY WITH AIR HOSE
2. REMOVE CLUTCH RELEASE CYLINDER AND LINE
CLAMP
(a) Remove the 2 bolts and release cylinder.
(b) Remove the 2 bolts and release cylinder line clamp.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
3. DISCONNECT GROUND CABLE
Remove the 2 bolts and disconnect the 2 ground cables from
the transaxle side and engine left mounting bracket side.
4. DISCONNECT BACK-UP LIGHT SWITCH CONNEC-
TOR
5. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
6. REMOVE STARTER SET BOLT
Remove the 2 set bolts of the starter from the transaxle upper
side.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
7. REMOVE TRANSAXLE MOUNTING BOLT
Remove the 3 bolts of transaxle case upper side.
Torque:
17 mm head: 64 N´m (650 kgf´cm, 47 ft´lbf)
8. INSTALL ENGINE SUPPORT FIXTURE
9. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
10. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
11. REMOVE LH AND RH ENGINE UNDER COVERS
12. DRAIN TRANSAXLE OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts)
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
13. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-17)

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)

MX07G-02
MX-6
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal.
HINT:
After installation, check and inspect items as follows.

Front wheel alignment (See page SA-4).

Do the road test.

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