TOYOTA TERCEL 1996 Service Repair Manual

Q07846
SSTSST
Q07552
SST
SST
25 mm
N00060
N00061
MX-18
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
(e) Using SST and a press, install a new bearing.
SST 09950- 60010 (09951- 00620), 09950- 70010
(09951-07150)
(f) Install the bearing lock plate and torque the bolt.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
6. INSTALL TRANSAXLE CASE RECEIVER
Install the transaxle case receiver and torque the bolt.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
7. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN
GEAR OIL SEAL
(a) Using SST, remove the oil seal.
SST 09921-00010
(b) Using SST, install a new oil seal.
SST 09201- 10000 (09201- 01080), 09950- 70010
(09951-07150)
Drive in depth: 25 mm (0.98 in.)
(c) Coat the lip of oil seal with MP grease.
8. C151:
IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Using a hexagon wrench, remove the straight screw plug.
(b) Using a pin punch and hammer, remove the slotted spring
pin.
(c) Replace the reverse restrict pin.
(d) Using a pin punch and hammer, install the slotted spring
pin.
(e) Apply sealant to the plug threads.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Using a hexagon wrench, install the straight screw plug.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

MX07K-03
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-19
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly.
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.

MX07L-01
Q06510
Needle Roller Bearing
Synchronizer Ring
No.2 Clutch HubInput Shaft
Needle Roller Bearing
4th Gear No.2 Hub Sleeve
3rd Gear
Shifting Key
Shifting Key Spring
Synchronizer Ring
Snap Ring
Rear Ball Bearing Snap Ring
MX-20
- MANUAL TRANSAXLEINPUT SHAFT
732 Author
: Date
:
1996 TERCEL (RM440U)
INPUT SHAFT
COMPONENTS

MX07M-01
Q05793
3rd Gear
4th Gear
N00065
Q06518
C141:C151:
SSTSocket Wrench
SST
- MANUAL TRANSAXLEINPUT SHAFT
MX-21
1996 TERCEL (RM440U)
DISASSEMBLY
1. INSPECT 3RD AND 4TH GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
3rd gear: 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
4th gear: 0.10 - 0.55 mm (0.0039 - 0.0217 in.)
Maximum clearance:
3rd gear: 0.40 mm (0.0157 in.)
4th gear: 0.60 mm (0.0236 in.)
2. INSPECT 3RD AND 4TH GEARS RADIAL CLEAR-
ANCE
Using a dial indicator, measure the radial clearance between
the gear and shaft.
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.
3. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, remove the snap ring.
4. REMOVE REAR BALL BEARING, 4TH GEAR, NEEDLE
ROLLER BEARING, SPACER AND SYNCHRONIZER
RING FROM INPUT SHAFT
(a) Using SST, a socket wrench (C141 only) and press, re-
move the rear ball bearing.
SST 09950-00020
(b) Remove the 4th gear, needle roller bearings, spacer and
synchronizer ring.
5. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, remove the snap ring.

CM0064
SST
CM0141
MX-22
- MANUAL TRANSAXLEINPUT SHAFT
1996 TERCEL (RM440U)
6. REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR,
SYNCHRONIZER RING AND NEEDLE ROLLER BEAR-
ING
Using SST and a press, remove the No.2 hub sleeve assembly,
3rd gear, synchronizer ring and needle roller bearings.
SST 09950-00020
7. REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO.2 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs
from the No.2 clutch hub.

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.

CM0066
AB
C
D
CM0013
MX-24
- MANUAL TRANSAXLEINPUT SHAFT
1996 TERCEL (RM440U)
3. INSPECT INPUT SHAFT
(a) Check the input shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the in-
put shaft journal surface.
Minimum outer diameter:
Part A (C151): 24.870 mm (0.9791 in.)
Part B: 28.970 mm (1.1405 in.)
Part C: 30.970 mm (1.2193 in.)
Part D: 24.970 mm (0.9831 in.)
If the outer diameter is less than the minimum, replace the input
shaft.
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 in.)
If the runout exceeds the maximum, replace the input shaft.

MX07O-02
D02999
Engine Side
Z08629
N00067
N00068
- MANUAL TRANSAXLEINPUT SHAFT
MX-25
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply gear oil to the needle roller bearings.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Using a press, install the 3rd gear and No.2 hub sleeve
assembly.
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
02.30 (0.0906)32.48 (0.0976)
12.36 (0.0929)42.54 (0.1000)
22.42 (0.0953)52.60 (0.1024)
(b) Using a screwdriver and hammer, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MX-21)

N00070
SM0049
SST
SM0050
MX-26
- MANUAL TRANSAXLEINPUT SHAFT
1996 TERCEL (RM440U)
5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER
BEARING, SPACER, 4TH GEAR AND REAR BALL
BEARING
(a) Apply gear oil to the needle roller bearings.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Using SST and a press, install the rear ball bearing.
SST 09608-00071
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.29 (0.0902)D2.47 (0.0972)
B2.35 (0.0925)E2.53 (0.0996)
C2.41 (0.0949)F2.59 (0.1020)
(b) Using a screwdriver and hammer, install the snap ring.
7. INSPECT 4TH GEAR THRUST CLEARANCE
(See page MX-21)

MX07P-01
Q06509
Needle Roller Bearing
1st Gear
No.1 Hub Sleeve
Shifting Key
No.1 Clutch Hub
Synchronizer RingOutput Shaft Assembly Ball
Thrust Washer
Synchronizer Ring
Needle Roller Bearing
2nd GearShifting Key Spring
Snap Ring
3rd Driven Gear
Output Gear Spacer
4th Driven Gear
Rear Ball Bearing
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-27
739 Author
: Date
:
1996 TERCEL (RM440U)
OUTPUT SHAFT
COMPONENTS