TOYOTA TERCEL 1996 Service Repair Manual

MX07Q-01
Q05794
2nd Gear
1st Gear
SM0137
CM0065
SST
N00074
MX-28
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
DISASSEMBLY
1. INSPECT 1ST AND 2ND GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear: 0.10 - 0.40 mm (0.0039 - 0.0157 in.)
2nd gear: 0.10 - 0.45 mm (0.0039 - 0.0177 in.)
Maximum clearance:
1st gear: 0.45 mm (0.0177 in.)
2nd gear: 0.50 mm (0.0197 in.)
2. INSPECT 1ST AND 2ND 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 REAR BALL BEARING, 4TH DRIVEN GEAR
AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT
(a) Using SST and a press, remove the rear ball bearing and
4th driven gear.
SST 09950-00020
(b) Remove the output gear spacer.
4. REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE
ROLLER BEARING AND SYNCHRONIZER RING
(a) Shift the No.1 hub sleeve into the 1st gear.

MT0063
SST
N00076
CM0142
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-29
1996 TERCEL (RM440U)
(b) Using SST and a press, remove the 3rd driven gear and
2nd gear.
SST 09950-00020
(c) Remove the needle roller bearing and synchronizer ring.
5. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, remove the snap ring.
6. REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR,
SYNCHRONIZER RING, NEEDLE ROLLER BEARING,
THRUST WASHER AND BALL
(a) Using a press, remove the No.1 hub sleeve assembly, 1st
gear and synchronizer ring.
(b) Remove the needle roller bearing, thrust washer and ball.
7. REMOVE NO.1 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO.1 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs
from the No.1 clutch hub.

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.

CM0015
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-31
1996 TERCEL (RM440U)
(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 output shaft.

MX07S-03
CM0009
Engine Side
N00077
N00078
N00079
MX-32
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the No.1 clutch hub and shifting keys to the No.1
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 BALL, THRUST WASHER, 1ST GEAR,
NEEDLE ROLLER BEARING, SYNCHRONIZER RING
AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT
SHAFT
(a) Install the ball to the shaft.
(b) Fit the thrust washer groove securely over the locking ball
when installing the thrust on the shaft.
(c) Apply gear oil to the needle roller bearing.
(d) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(e) Using a press, install the 1st gear and No.1 hub sleeve.

N00080
N00083
N00084
N00086
SST
- MANUAL TRANSAXLEOUTPUT SHAFT
MX-33
1996 TERCEL (RM440U)
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.50 (0.0984)D2.68 (0.1055)
B2.56 (0.1008)E2.74 (0.1079)
C2.62 (0.1031)F2.80 (0.1102)
(b) Using a screwdriver and hammer, install the snap ring.
4. INSPECT 1ST GEAR THRUST CLEARANCE
(See page MX-28)
5. INSTALL SYNCHRONIZER RING, 2ND GEAR,
NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR
(a) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(b) Apply gear oil to the needle roller bearing.
(c) Install the 2nd gear.
(d) Using a press, install the 3rd driven gear.
6. INSPECT 2ND GEAR THRUST CLEARANCE
(See page MX-28)
7. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN
GEAR AND REAR BALL BEARING
(a) Install the output gear spacer.
(b) Using SST and a press, install the 4th driven gear and
rear ball bearing.
SST 09608-00071

MX07T-01
Q05961
Boot
Shift and Select Lever
Shaft
Control Shaft Cover
Snap Ring
Oil Seal

Gasket
Spring
No.2 Select Spring
Seat
Spring
E-Ring

Non-reusable part
Apply MP greaseSlotted Spring PinNo.1 Shift Inner LeverSlotted Spring Pin No.1 Select Spring Seat
No.2 Shift Inner LeverSelect Inner Lever
Shift Interlock
Plate
MX-34
- MANUAL TRANSAXLESHIFT AND SELECT LEVER SHAFT
746 Author
: Date
:
1996 TERCEL (RM440U)
SHIFT AND SELECT LEVER SHAFT
COMPONENTS

MX07U-03
Q06511

Oil Seal
Plate Washer

Outer Race and Side Bearing
Speedometer Drive Gear
Straight Pin

Side Bearing and Outer Race

Oil Seal
Ring Gear Plate Washer Differential Case Pinion Shaft
Pinion Gear
Thrust Washer
Side Gear
Thrust Washer

Non-reusable partx6
- MANUAL TRANSAXLEDIFFERENTIAL CASE
MX-35
747 Author
: Date
:
1996 TERCEL (RM440U)
DIFFERENTIAL CASE
COMPONENTS

MX07V-03
Z16129
SST
MT0081
Matchmarks
MT0083
MT0084
N00098
SST MX-36
- MANUAL TRANSAXLEDIFFERENTIAL CASE
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
(a) Using SST, remove the bearings from both sides of the
case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00360)
(b) Remove the speedometer drive gear from the RH side.
2. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and case.
(b) Remove the 6 bolts.
(c) Using a plastic hammer, remove the ring gear from the
case.
3. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear
while holding one pinion toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specification, install the correct
thrust washer to the side gears.
4. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, remove the pinion shaft
straight pin.
(b) Remove the pinion shaft from the case.
(c) Remove the 2 pinion gears and side gears with the 4
thrust washers from each gear.
5. Transmission Case Side:
IF NECESSARY, REPLACE OIL SEAL AND SIDE
BEARING OUTER RACE
(a) Using a screwdriver and hammer, remove the oil seal.
(b) Using SST, remove the outer race and plate washer.
SST 09612-65014
(c) Place the plate washer into the case.

Q08120
SST
Q08121
SST 2.4 ± 0.3 mm
N00100
SST
Z16127
SST
Q06517
SST 1.9 ± 0.3 mm
- MANUAL TRANSAXLEDIFFERENTIAL CASE
MX-37
1996 TERCEL (RM440U)
(d) Using SST and a hammer, install a new outer race.
SST 09950- 60020 (09951- 00710), 09950- 70010
(09951-07150)
(e) Using SST and a hammer, install a new oil seal.
SST 09350-32014 (09351-32111, 09351-32130)
Drive in depth: 2.4 ± 0.3 mm (0.094 ± 0.012 in.)
(f) Coat the lip of the oil seal with MP grease.
6. Transaxle Case Side:
IF NECESSARY, REPLACE OIL SEAL AND SIDE
BEARING OUTER RACE
(a) Using a screwdriver and hammer, remove the oil seal.
(b) Using SST, remove the outer race and plate washer.
SST 09612-65014
(c) Place the plate washer into the case.
(d) Using SST and a hammer, install a new outer race.
SST 09950- 60020 (09951- 00680), 09950- 70010
(09951-07150)
(e) Using SST and a hammer, install a new oil seal.
SST 09350-32014 (09351-32130, 09351-32150)
Drive in depth: 1.9 ± 0.3 mm (0.075 ± 0.012 in.)
(f) Coat the lip of the oil seal with MP grease.