TOYOTA TERCEL 1996 Service Repair Manual

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)

Q10103
Reverse Shift Arm
BracketReverse Shift Fork
Snap RingSnap Ring
Thrust Washer Reverse Idler Gear
Idler Gear Shaft
Ball (C151)Straight Screw Plug


BallSpringSeat


No.3 Shift Fork
(C151)

No.2 Shift Fork Shaft
Output Shaft Assembly
Shift HeadNo.1 Shift Fork Shaft
No.1 Shift Fork
No.2 Shift Fork
Lock Nut (C141)

5th Driven Gear
(C151)
x5
Spacer Snap Ring
Rear Bearing Retainer
Needle Roller Bearing
5th GearSynchronizer Ring
No.3 Hub Sleeve
Shifting Key
 Non-reusable part

Precoated partNo.3 Clutch
Hub
Snap Ring
Shifting Key SpringLock Nut (C151) 
Input Shaft AssemblySnap Ring
Spacer (C141)
No.3 Shift Fork Shaft Snap Ring (C151)
Snap RingSloted Spring Pin (C141)
(C151)
C151:
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-9
721 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.

Q06523
Lock Bolt
Q06512
Q06531
SST
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-1 1
1996 TERCEL (RM440U)
9. REMOVE SHIFT AND SELECT LEVER SHAFT AS-
SEMBLY
(a) Remove the lock bolt.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(b) Remove the 4 bolts and pull out the shift and select lever
shaft assembly with the gasket.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N´m (200 kgf´cm, 14 ft´lbf)
10. REMOVE LOCK NUT
(a) Engage the gear double meshing.
(b) Using a hammer and chisel, loosen the staked part of the
nut.
(c) Remove the lock nut.
Torque: 118 N´m (1,200 kgf´cm, 87 ft´lbf)
(d) C141:
Remove the spacer.
(e) Disengage the gear double meshing.
11. C151:
REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the bolt from the No.3 shift fork.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(b) Remove the No.3 hub sleeve and shift fork.
12. C151:
REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.25 (0.0886)E2.49 (0.0980)
B2.31 (0.0909)F2.55 (0.1004)
C2.37 (0.0933)G2.61 (0.1028)
D2.43 (0.0957)--
(b) Using SST, remove the 5th gear, No.3 clutch hub, syn-
chronizer ring, needle roller bearings and spacer.
SST 09950-40010

Q06532
SST
Engine Side
Q06533
SST
Socket Wrench
N00174
SST
SST
Q06514
x5 MX-12
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
HINT:

Install the No.3 clutch hub and shifting keys to the hub
sleeve.

Install the shifting key springs under the shifting keys.
NOTICE:
At the time of reassembly, position the key springs so that
their end gaps are not in line.

Support the tip of the input shaft with a spacer or such
to raise the transaxle assembly.

Using SST and a hammer, drive in the No.3 hub sleeve
assembly with the No.3 shift fork.
SST 09612-2201 1
NOTICE:
At the time of reassembly, align the synchronizer ring slots
with the shifting keys.
13. C151:
REMOVE 5TH DRIVEN GEAR
Using SST and a socket wrench, remove the 5th driven gear.
SST 09950-40010
HINT:
At the time of reassembly, please refer to the following item.
Using SST, install the 5th driven gear.
SST 09309-12020
14. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and retainer.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
15. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.
HINT:
If it is difficult to remove and install the snap rings, pull up the
shafts.

MT0057
Q06516
C141 Only
Q06524
Z00668
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-13
1996 TERCEL (RM440U)
16. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
17. REMOVE SNAP RING FROM NO.2 SHIFT FORK
SHAFT
Using 2 screwdrivers and a hammer, remove the snap ring.
18. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING
AND BALL
(a) Using a hexagon wrench, remove the 4 plugs.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
C141 Plug, As Shown:
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) Using a magnetic finger, remove the 3 seats, springs and
balls.
19. REMOVE STRAIGHT SCREW PLUG (C141) OR LOCK
BALL ASSEMBLY (C151)
Using a hexagon wrench, remove the straight screw plug
(C141) or lock ball assembly (C151).
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
20. REMOVE TRANSMISSION CASE
(a) Remove the 16 bolts.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(b) Carefully tap the transmission case with a plastic hammer
and remove it.

MT0094
FIPG
Q08153
MT0093Align Alignment Mark
Q06515
C151 Only
N00045
MX-14
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent
21. REMOVE REVERSE IDLER GEAR, THRUST WASHER
AND SHAFT
22. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and bracket.
Torque: 17 N´m (175 kgf´cm, 13 ft´lbf)
HINT:
Install the reverse idler gear, thrust washer and shaft, as shown.
23. REMOVE SHIFT FORK AND SHIFT FORK SHAFT
(a) Using 2 screwdrivers and a hammer, tap out the 3 (C151)
or 2 (C141) snap rings.
(b) Remove the 3 set bolts.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(c) C141:
Using a pin punch and hammer, remove the slotted spring
pin from the reverse shift fork.
(d) Remove the No.2 shift fork shaft and shift head.

N00047
CM0141
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-15
1996 TERCEL (RM440U)
(e) C151:
Using a magnetic finger, remove the 2 balls from the re-
verse shift fork.
(f) Remove the No.3 shift fork shaft and reverse shift fork.
(g) Pull out the No.1 shift fork shaft.
(h) Remove the No.1 and No.2 shift forks.
24. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER
FROM TRANSAXLE CASE
25. REMOVE DIFFERENTIAL CASE ASSEMBLY
HINT:
Before reassembly, inspect the differential side bearing pre-
load.
26. REMOVE MAGNET FROM TRANSAXLE CASE
27. REMOVE NO.3 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO.3 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs
from the No.3 clutch hub.

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

N00160
SSTSST
Z16126
SST 15.8 ± 0.2 mm
Q07845
SST
N00162
SSTSST
N00056
Case Cover
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-17
1996 TERCEL (RM440U)
(b) Using SST, remove the oil seal.
SST 09612-65014
(c) Using SST and a hammer, install a new oil seal.
SST 09950- 60010 (09951- 00360), 09950- 70010
(09951-07150)
Drive in depth: 15.8 ± 0.2 mm (0.622 ± 0.008 in.)
(d) Coat the lip of the oil seal with MP grease.
(e) Using SST and a press, install a new bearing.
SST 09950- 60010 (09951- 00460), 09950- 70010
(09951-07150)
5. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT
BEARING AND OUTPUT SHAFT COVER
(a) Remove the bolt and bearing lock plate.
(b) Using SST, remove the bearing.
SST 09308-00010
(c) Remove the output shaft cover.
(d) Install the output shaft cover.
HINT:
Install the output shaft cover projection into the case side hol-
low.