TOYOTA TERCEL 1996 Service Repair Manual

AX-8
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
EVALUATION
ProblemPossible cause
If governor pressure defect.
 Line pressure defect
 Fluid leakage in governor pressure circuit
 Governor valve operation defect
Vehicle speed (Reference)Governor pressure
30 km/h (19 mph)59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
60 km/h (37 mph)186 - 365 kPa (1.9 - 2.7 kgf/cm2, 27 - 38 psi)
90 km/h (56 mph)353 - 431 kPa (3.6 - 4.4 kgf/cm2, 51 - 63 psi)
6. ROAD TEST
NOTICE:
Do this test at normal fluid temperature 50 - 80 °C (122 - 176 °F).
(a) D position test.
Shift into the D position and while driving with the accelerator pedal held constant at the throttle valve
fully open, check on the following points:
(1) Check to seethat the 1"2 and 2"3 up-shifts take placeand also that the shift points conform
to those shown in the automatic shift schedule (See page SS-28).
EVALUATION
ProblemPossible cause
If there is no 1 - 2 up-shift. Governor valve is defective
 1 - 2 shift valve is stuck
If there is no 2 - 3 up-shift. 1 - 2 shift valve is stuck
If the shift point is defective.Throttle cable out of adjustment
 Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, etc. are defective
(2) In the same way, check the shock and slip at 1 " 2 and 2 " 3 up-shifts.
EVALUATION
ProblemPossible cause
If the shock is severe.
 Line pressure is too high
 Accumulator is defective
 Check ball is defective
(3) Run in the 3rd gear of the D position, check the abnormal noise and vibration.
HINT:
Check for the cause of abnormal noise and vibration must be made with extreme care as they could also
be due to imbalance in the drive shaft, differential, tires and torque converter clutch, etc.
(4) While running in the 3rd gear of the D position, check that the possible kick-down vehicle speed
limits for the 3 " 1 and 3 " 2 kick-down conform to those indicated in the automatic shift sched-
ule (See page SS-28).
EVALUATION
ProblemPossible cause
If the possible kick-down vehicle speed limit is defective. Throttle cable out of adjustment
 Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, etc. are defective
(5) Check the abnormal shock and slip at kick-down.
(6) While running at about 60 km/h (37 mph) in the 3rd gear of the D position, release your foot from
the accelerator pedal and shift into the L position. Then check if the 2 "1 down-shift point con-
forms to that indicated in the automatic shift schedule (See page SS-28).
(b) Inspect the lock-up mechanism.
(1) Drive in the D position at a steady speed (Lock-up ON) of about 65 km/h (40 mph).
(2) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly.

- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-9
1996 TERCEL (RM440U)
If there is a big jump in engine RPM, there is no lock-up.
(c) 2 position test.
(1) While running in the 2nd gear of the 2 position, release the accelerator pedal and check the en-
gine braking effect.
EVALUATION
ProblemPossible cause
If these is no engine braking effect. 2nd coast brake is defective.
(2) Check the abnormal noise during acceleration and deceleration.
(3) Check the shock during up-shift and down-shift.
(d) L position test.
(1) While running in the L position, check that there is no up-shift to 2nd gear.
(2) While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
EVALUATION
ProblemPossible cause
If these is no engine braking effect. 1st coast brake is defective.
(3) Check for abnormal noise during acceleration and deceleration.
(e) R position test.
Shift into the R position and, while running at full throttle, check for slipping.
(f) P position test.
Stop the vehicle on a gradient (more than 5°) and, after shifting into the P position, release the parking
brake. Then check to see that the parking lock pawl prevents the vehicle from moving.

AX08D-04
AX-10
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
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
Does not move in any forward position
5. Governor valve
6. Forward clutch (C
1)
7. No.2 one-way clutch (F
2)
8. 1st & reverse brake (B
3)
9. 2nd coast brake (B
1)
10.No.1 one-way clutch (F
1)
11. Direct clutch (C
2)
AX-17












Does not move in reverse position
1. 2nd coast brake (B1)
2. Front planetary gear
3. Rear planetary gear
4. 1 - 2 shift valve
5. 2 - 3 shift valve
6. Direct clutch (C
2)
7. 1st and reverse brake (B
3)














Does not move in any forward position or reverse position
1. Parking lock pawl
2. Manual valve
3. Front planetary gear
4. Rear planetary gear
5. Torque converter clutch







AX-30
No-up shift
(1st " 2nd)1. 1 - 2 shift valve
2. 2nd brake (B
2)
3. No.1 one-way clutch (F
1)






No-up shift
(2nd " 3rd)1. 2 - 3 shift valve
2. Direct clutch (C
2)




No-down shift
(3rd " 2nd)1. Throttle valve
2. 2 - 3 shift valve



No-down shift
(2nd " 1st)1. Throttle valve
2. 1 - 2 shift valve



Shift point too high or too low
1. Governor valve
2. 1 - 2 shift valve
3. 2 - 3 shift valve





Harsh engagement
(N " R)1. Direct clutch (C2)
2. 1st & reverse brake (B
3)




Harsh engagement
(N " D)1. Forward clutch (C1)
2. C
1 accumulator




Harsh engagement
(N " L)
1. Low coast modulator valve
2. Forward clutch (C
1)
3. C
1 accumulator
4. 1st & reverse brake (B
3)








Harsh engagement
(1st " 2nd ºDº position)1. B2 accumulator
2. 2nd brake (B
2)




Harsh engagement
(1st " 2nd º2º position)1. 2nd coast modulator valve
2. B
2 accumulator
3. 2nd brake (B
2)






Harsh engagement (1st " 2nd " 3rd)Throttle modulator valve

Harsh engagement (2nd " 3rd)Direct clutch (C2)

Harsh engagement
(3rd " 2nd)1. 2nd coast modulator valve
2. Primary regulator valve

- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-1 1
1996 TERCEL (RM440U)Symptom
Suspect AreaSee page
Slip
(Forward & Reverse)1. Torque converter clutch
2. Pressure relief valve
3. Oil strainerAX-30


AX-12
Slip (ºRº position)Direct clutch (C2)

Slip
(1st)1. Forward clutch (C1)
2. No.2 one-way clutch (F
2)




Slip
(2nd)1. Forward clutch (C1)
2. 2nd brake (B
2)
3. No.1 one-way clutch (F
1)






Slip
(3rd)1. Forward clutch (C1)
2. Direct clutch (C
2)
3. 2nd brake (B
2)






No engine braking (1st ºLº position)1st & reverse brake (B3)

No engine braking (2nd º2º position)2nd coast brake (B1)

No kick-down1. 1 - 2 shift valve
2. 2 - 3 shift valve



Poor accelerationTorque converter clutchAX-30
No lock-up
1. Lock-up relay
2. Lock-up signal valve
3. Torque converter clutch



AX-30

: Refer to A131L, A132L Automatic Transaxle Repair Manual (Pub. No. RM386U).

Q02558
AX0RJ-02
Q04924
Z15675
A
B
C
AT4869
A
B
C
D
A
BC
D AX-12
- AUTOMATIC TRANSAXLE (A132L)VALVE BODY ASSEMBLY
764 Author
: Date
:
1996 TERCEL (RM440U)
VALVE BODY ASSEMBLY
ON-VEHICLE REPAIR
1. DRAIN TRANSAXLE FLUID
Using a hexagon wrench, remove the drain plug and drain the
fluid into the suitable container.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
2. REMOVE OIL PAN AND GASKET
NOTICE:
Some fluid will remain in the oil pan. Remove the oil pan
bolts, and carefully remove the oil pan assembly. Discard
the gasket.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
3. EXAMINE PARTICLES IN PAN
Remove the magnets and use then to collect any steel chips.
Look at the chips on the magnet carefully to anticipate what
type of wear you will find in the transaxle.
Steel (magnetic) ...... bearing, gear and plate wear
Brass (non-magnetic) ..... bushing wear
4. REMOVE OIL STRAINER
Remove the 3 bolts and the oil strainer.
NOTICE:
Be careful as some oil will come out of the strainer.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. REMOVE OIL PIPES
(a) Remove the 2 bolts and pipe bracket.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(b) Pry up the both pipe ends with a large screwdriver and re-
move the 4 pipes.
NOTICE:
Be careful not to bend or damage the pipes.

Q05798
Z10919
B
A
C
BDBD B C
OR0038
AT2796
Gasket
Strainer
- AUTOMATIC TRANSAXLE (A132L)VALVE BODY ASSEMBLY
AX-13
765 Author
: Date
:
1996 TERCEL (RM440U)
6. REMOVE MANUAL DETENT SPRING
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
HINT:
Check that the manual valve lever is in contact with the center
of the roller at the tip of the detent spring.
7. REMOVE MANUAL VALVE AND MANUAL VALVE
BODY
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
8. REMOVE VALVE BODY
(a) Remove the14 bolts.
Bolt Length:
A: 20 mm (0.79 in.)
B: 25 mm (0.98 in.)
C: 36 mm (1.47 in.)
D: 50 mm (1.97 in.)
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(b) Disconnect the throttle cable.
NOTICE:
Be careful not to entangle the kick-down switch and sole-
noid wire.
(c) Remove the valve body.
9. REMOVE SECOND BRAKE APPLY GASKET AND
GOVERNOR OIL STRAINER
HINT:
Replace the used gasket with anew one.

AX0RK-01
AX-14
- AUTOMATIC TRANSAXLE (A132L)VALVE BODY ASSEMBLY
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of the previous steps.
HINT:
After installation, fill ATF and check the fluid level (See page AX-2).

Q06544
N00513
N00515
0.8 - 1.5 mm
200 mm
AX0RL-01
- AUTOMATIC TRANSAXLE (A132L)THROTTLE CABLE
AX-15
767 Author
: Date
:
1996 TERCEL (RM440U)
THROTTLE CABLE
ON-VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM ENGINE
Disconnect the cable from the throttle linkage.
2. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Disconnect the transaxle control cable from the transaxle
control shaft lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(b) Remove the nut and transaxle control shaft lever.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(c) Using a screwdriver, pry off the nut stopper.
(d) Remove the nut and nut stopper.
Torque: 6.9 N´m (70 kgf´cm, 61 in.´lbf)
(e) Remove the 2 bolts and park/neutral position switch.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
3. REMOVE VALVE BODY (See page AX-12)
4. REMOVE THROTTLE CABLE
(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.
HINT:
New cables does not habe a cable stopper staked.
(c) Bend the cable so that there is a radius of about 200 mm
(7.87 in.).
(d) Pull the inner cable lightly nutil a slight resistance is felt,
and hold it there.
(e) Stake the stoppe, 0.8-1.5 mm (0.031-0.059 in.) from the
end of outer cable.

AX0RM-01
AX-16
- AUTOMATIC TRANSAXLE (A132L)THROTTLE CABLE
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of the previous steps.
HINT:

After installation, adjust the throttle cable (See page AX-2).

Test drive the vehicle.

AT1012
Governor
Bracket
AX0RN-01
AT2709
Adaptor
Plate Washer
O-RingThrust Washer
Cover
- AUTOMATIC TRANSAXLE (A132L)GOVERNOR VALVE
AX-17
769 Author
: Date
:
1996 TERCEL (RM440U)
GOVERNOR VALVE
ON-VEHICLE REPAIR
1. REMOVE TRANSAXLE DUST COVER
2. DISCONNECT LH DRIVE SHAFT
(See page SA-18)
3. REMOVE GOVERNOR BRACKET
4. REMOVE GOVERNOR COVER WITH O-RING
HINT:
Replace the used O-ring with a new one.
5. REMOVE GOVERNOR BODY WITH THRUST WASHER
6. REMOVE PLATE WASHER
7. REMOVE GOVERNOR BODY ADAPTOR