ABS TOYOTA TERCEL 1996 Service Manual PDF

W00656
SST
R11683
- SUSPENSION AND AXLEFRONT AXLE HUB
SA-1 1
1996 TERCEL (RM440U)
8. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE
(a) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09628-6201 1
9. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM
Remove the 2 nuts and bolt.
Torque: 80 N´m (820 kgf´cm, 59 ft´lbf)
10. REMOVE STEERING KNUCKLE WITH AXLE HUB
(a) Remove the 2 nuts and bolts on lower side of the shock
absorber.
(b) Remove the steering knuckle with the axle hub.
NOTICE:
Be careful not to damage the oil seal with the drive shaft.

SA117-02
- SUSPENSION AND AXLEFRONT AXLE HUB
SA-15
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-10).
HINT:
After installation, check ABS speed sensor signal (See page DI-1 11 and SA-4).

SA128-02
FA1535
SST
F03986
SA-18
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
REMOVAL
NOTICE:

The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed. Therefore, if it is
absolutely necessary to place the vehicle weight on
the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)

w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the sensor rotor
serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. M/T:
REMOVE LH ENGINE UNDER COVER
3. DRAIN TRANSAXLE OIL (M/T) OR ATF (A/T)
4. w/ ABS:
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
5. REMOVE DRIVE SHAFT LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) While applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
6. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE (See page SA-10)
7. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See page SA-10)
8. DISCONNECT DRIVE SHAFT FROM AXLE HUB
NOTICE:
Be careful not to damage the drive shaft boot and inner oil
seal.

SA129-06
N00191
R11817
Matchmarks
N00194
Matchmarks
R09716
SST SA-20
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 TERCEL (RM440U)
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no play in the outboard joint.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no remarkable play in the radial
direction of the inboard joint.
2. REMOVE INBOARD JOINT TULIP
(a) Using a screwdriver, remove the 2 boot clamps.
(b) Place matchmarks on the inboard joint tulip and tripod.
(c) Remove the inboard joint tulip from the drive shaft.
3. REMOVE TRIPOD
(a) Using a snap ring expander, remove the snap ring.
(b) Place matchmarks on the shaft and tripod.
(c) Using a brass bar and hammer, remove the tripod joint
from the drive shaft.
4. REMOVE INBOARD JOINT BOOT AND 2 BOOT
CLAMPS
5. RH DRIVE SHAFT:
REMOVE DYNAMIC DAMPER
(a) Using a screwdriver, remove the damper clamp.
(b) Remove the damper from the drive shaft.
6. REMOVE OUTBOARD JOINT BOOT
(a) Using a screwdriver, remove the 2 boot clamps.
(b) Remove the boot and 2 boot clamp from the outboard
joint.
NOTICE:
Do not disassemble the outboard joint.
7. REMOVE DUST COVER
Using SST and a press, remove the dust cover from the inboard
joint tulip.
SST 09950-00020
8. w/o ABS:
REMOVE NO.2 DUST DEFLECTOR
(a) Mount the outboard joint in a soft jaw vise.
(b) Using a screwdriver, remove the No.2 dust deflector.

R11822
SST
SA12A-05
SA1459
R09694
Inboard Joint Boot Outboard Joint Boot
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA-21
1996 TERCEL (RM440U)
REASSEMBLY
1. w/o ABS:
INSTALL DUST DEFLECTOR NO.2
Using SST and a press, install a new dust deflector No.2.
SST 09309-36010, 09316-20011
2. INSTALL DUST COVER
Using a press, install a new dust cover to the inboard joint tulip.
3. TEMPORARILY INSTALL BOOTS, CLAMPS AND
DAMPER (RH DRIVE SHAFT)
HINT:
Before installing the boots, wrap vinyl tape around the spline of
the drive shaft to prevent damaging the boot.
(a) Temporarily install a new outboard joint boot.
(b) RH drive shaft:
Temporarily install the damper.
(c) Temporarily install a new inboard joint boot.
4. INSTALL TRIPOD
(a) Place the beveled side of the tripod axial spline toward the
outboard joint.
(b) Align the matchmarks before removal.
(c) Using a brass bar and hammer, tap in the tripod to the
drive joint shaft.
NOTICE:
Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
5. INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, pack the outboard joint and boot
with grease in the boot kit.
Grease capacity: 65 - 75 g (2.3 - 2.6 oz.)
6. INSTALL INBOARD JOINT TO FRONT DRIVE SHAFT
(a) Pack the inboard tulip and boot with grease in the boot kit.
Grease capacity: 112 - 122 g (4.0 - 4.3 oz.)
(b) Align the matchmarks as they were placed before disas-
sembly
(c) Install the inboard joint tulip to the drive shaft.
(d) Temporarily install the boot to the inboard joint shaft.

SA12B-02
- SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA-23
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-18).
HINT:
After installation, check ABS speed sensor signal and front wheel alignment (See page DI-1 11 and
SA-4).

SA119-05
SA-24
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
840 Author
: Date
:
1996 TERCEL (RM440U)
FRONT SHOCK ABSORBER
COMPONENTS

SA1W8-02
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA-25
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. REMOVE FLEXIBLE HOSE
Remove the bolt and disconnect the flexible hose from the shock absorber.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
3. w/ ABS:
DISCONNECT ABS SPEED SENSOR WIRE HARNESS
Remove the bolt and disconnect the ABS speed sensor wire harness from the shock absorber.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
4. DISCONNECT SHOCK ABSORBER FROM STEERING KNUCKLE
Remove the 2 nuts and bolts and disconnect the shock absorber from steering knuckle,
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
HINT:
Coat the nut's threads with engine oil.
5. REMOVE SHOCK ABSORBER AND COIL SPRING
(a) Remove the 3/4 nuts on the upper side of the shock absorber.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Remove the shock absorber with the coil spring.

F02799
SST
SA1W9-01
W03398
SST SA-26
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 TERCEL (RM440U)
DISASSEMBLY
REMOVE COIL SPRING
(a) Using SST, compress the coil spring.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Install 2 nuts and bolt to the bracket at the lower part of
the shock absorber and secure it in a vise.
(c) Using SST, to hold the spring seat, remove the nut.
SST 09729-22031
(d) Remove these parts:

Suspension support.

Dust seal.

Spring seat.

Upper insulator.

Coil spring.

Spring bumper.

Lower insulator.

SA11C-02
R11754
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA-27
1996 TERCEL (RM440U)
INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual operation sound.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When disposing of the shock absorber, use the following
procedure.