TOYOTA TERCEL 1996 Service Repair Manual

AX-8
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U)
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 there is no 3 - O/D up-shift
(throttle valve operating less than 86%).
3 - O/D shift valve is stuck

Solenoid valve or circuit defective
If the shift point is defective.

Throttle cable out of adjustment

Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, 3 - O/D shift valve etc. are
defective
(2) In the same way, check the shock and slip at 1 " 2, 2 " 3 and 3 "O/D 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 or O/D 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 unbalance in the drive shaft, differential, tires and torque converter clutch, etc.
(4) While running in the 3rd gear or O/D of the D position, check that the possible kick-down vehicle
speed limits for the 3 " 1, 3 " 2 and O/D "2 kick-down conform to those indicated in the auto-
matic shift schedule (See page SS-30).
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, 3 - O/D 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 O/D 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 conforms
to that indicated in the automatic shift schedule (See page SS-30).
(b) Inspect the lock-up mechanism.
(1) Drive in the D position at a steady speed (Lock-up ON) of about 70 km/h (43 mph).
(2) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly.
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.

- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-9
1996 TERCEL (RM440U)
EVALUATION
ProblemPossible cause
If these is no engine braking effect.
1st & reverse 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 that the parking lock pawl prevents the vehicle from moving.

AX-10
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U)
7. ELECTRIC CONTROL SYSTEM

BE1485
432
1
5
6 7
8 9
Q06563
ON
OFF
O/D Main
SwitchIndicator
Light
Q01167
Q01168
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-1 1
1996 TERCEL (RM440U)
(a) Inspect the Park/Neutral position switch.
(1) Remove the park/neutral position switch
(See page AX-19).
(2) Using an ohmmeter, check continuity between each
terminal shown below when the shift lever is put in
each position.
If the continuity is not as specified, replace the switch.
(b) Inspect the O/D OFF indicator light.
(1) Turn the ignition switch ON.
(2) The O/D OFF indicator light will come on when the
O/D main switch is in OFF position.
(3) The O/D OFF indicator light will go on when the O/D
main switch is placed at ON.
(c) Inspect the O/D solenoid valve.
(1) Disconnect the solenoid connector.
(2) Using an ohmmeter, measure the resistance be-
tween terminals 1 and 3.
Resistance: 11 - 15 W
If the resistance is not as specified, replace the solenoid.
(3) Apply battery positive voltage between terminals 1
and 3. At this time, confirm that a solenoid operation
sound is heard.
If the operation is not as specified, replace the solenoid.
(4) Connect the solenoid connector.

Q06564
4
2 AX-12
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U)
(d) Inspect the O/D main switch.
(1) Remove the center console box.
(2) Using an ohmmeter, check that the continuity of the
terminals 2 and 4 for each switch position.
Switch positionTester connectionSpecified condition
ON2 - 4No continuity
OFF2 - 4Continuity
If the continuity is not as specified, replace the switch.
(3) Install the center console box.

AX07X-05
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-13
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.
ON-VEHICLE:
SymptomSuspect AreaSee page
Does not move in any forward position
4. Forward clutch (C1)
5. No.2 one-way clutch (F
2)
6. 1st & reverse brake (B
3)
7. 2nd brake (B
2)
8. 2nd coast brake (B
1)
9. Direct clutch (C
2)












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. U/D clutch (C
3)
8. 1st and reverse brake (B
3)
















Does not move in any forward position or reverse position
1. Parking lock pawl
2. Manual valve
3. U/D one-way clutch (F
3)
4. U/D clutch (C
3)
5. U/D brake (B
0)
6. Front planetary gear
7. Rear planetary gear
8. U/D planetary gear
9. Torque converter clutch
















AX-34
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-up shift
(3rd " O/D)1. U/D brake (B0)
2. 3 - 4 shift valve



No-down shift
(O/D " 3rd)3 - 4 shift valve

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

No-down shift
(2nd " 1st)1. 1 - 2 shift valve
2. 2nd coast brake (B
1)




Shift point too high or too low
1. Governor valve
2. 1 - 2 shift valve
3. 2 - 3 shift valve
4. 3 - 4 shift valveAX-21






Up-shifts 3rd " O/D with O/D main switch ''OFF''Electric control systemAX-2
Harsh engagement
(N " R)1. Direct clutch (C2)
2. 1st & reverse brake (B
3)
3. Accumulator control valve






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




Harsh engagement
(N " L)Low coast modulator valve

AX-14
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U) Harsh engagement
(1st " 2nd ºDº position)
1. B2 accumulator
2. 1st and reverse brake (B
3)




Harsh engagement
(1st " 2nd º2º position)2nd coast modulator valve

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



Harsh engagement
(1st " 2nd " 3rd " O/D)Accumulator control valve

Harsh engagement
(2nd " 3rd)1. 2nd coast brake (B1)
2. C
2 accumulator




Harsh engagement
(3rd " O/D)
1. U/D clutch (C3)
2. U/D brake (B
4)
3. U/D planetary gear
4. B
4 accumulator








Harsh engagement
(O/D " 3rd)1. B4 accumulator
2. C
3 accumulator




Harsh engagement
(3rd " 2nd)
1. B4 accumulator
2. C
3 accumulator
3. 2nd coast modulator valve
4. B
2 accumulator
5. 1st and reverse brake










No lock-up1. Lock-up relay valve
2. Torque converter clutch

AX-34
No lock-up OFF1. Lock-up relay valve
2. Torque converter clutch

AX-34
Slip or shudder
(Forward & Reverse After warm-up)1. Torque converter clutch
2. U/D one-way clutch (F
3)
3. U/D clutch (C
3)
AX-34




Slip or shudder
(Forward & Reverse Directly after E/G start)1. Torque converter clutch
2. Pressure relief valve
3. Oil strainerAX-34


AX-16
Slip or shudder
(''R'' position)1. Direct clutch (C2)
2. U/D clutch (C
3)
3. 1st and reverse brake






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




Slip or shudder
(2nd)1. C2 accumulator
2. 2nd brake (B
2)
3. No.1 one-way clutch (F
1)






Slip or shudder
(2nd "3rd Up-shift)Direct clutch (C2)

Slip or shudder
(3rd)Direct clutch (C2)

Slip or shudder
(O/D)U/D brake (B4)

No engine braking
(1st "3rd)U/D clutch (C3)

No engine braking
(1st)1. Low coast modulator valve
2. 1st and reverse brake



No engine braking
(2nd)1. 2nd coast brake (B1)
2. 2nd coast modulator valve

- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-15
1996 TERCEL (RM440U)
OFF-VEHICLE:
SymptomSuspect AreaSee page
Large shock during lock-upTorque converter clutchAX-34
E/G stalls when starting off and stoppingTorque converter clutchAX-34
Poor acceleration
(All-positions)Torque converter clutchAX-34
Poor acceleration
(O/D)1. U/D clutch (C3)
2. U/D planetary gear



Poor acceleration
(Other than O/D)1. U/D brake (B4)
2. U/D planetary gear



Poor acceleration
(Other than 2nd)1. 2nd coast brake (B1)
2. 2nd brake (B
2)




Poor acceleration
(1st and 2nd)Direct clutch (C2)

Poor acceleration
(1st and ''R'')1st and reverse brake (B3)

Poor acceleration
(''R'')Forward clutch (C1)


: Refer to A242L Automatic Transaxle Repair Manual (Pub. No. RM431U).

AT3320
AX0RX-01
Q06911
Z15036
20 (0.79)
12 (0.47)25 (0.98)
20 (0.79)
AT3329
AX-16
- AUTOMATIC TRANSAXLE (A242L)VALVE BODY ASSEMBLY
798 Author
: Date
:
1996 TERCEL (RM440U)
VALVE BODY ASSEMBLY
ON-VEHICLE REPAIR
1. DRAIN ATF
Remove the drain plug and drain the ATF into the suitable con-
tainer.
Torque: 17 N´m (175 kgf´cm, 13 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 AND APPLY PIPE BRACKET
(a) Remove the 3 bolts and oil strainer.
NOTICE:
Be careful as some oil will come out of the strainer.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(b) Remove the 2 bolts and apply pipe bracket.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. REMOVE OIL PIPES
(a) Remove the clamp bolt.
(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.

AT3328
Z15031
B
B
A
C
A AA
B
OR0038
AT5616
AT2713
- AUTOMATIC TRANSAXLE (A242L)VALVE BODY ASSEMBLY
AX-17
799 Author
: Date
:
1996 TERCEL (RM440U)
6. REMOVE MANUAL DETENT SPRING
Remove the bolt and 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. DISCONNECT SOLENOID CONNECTOR
8. REMOVE VALVE BODY
(a) Remove the 12 bolts.
Bolt length:
A: 20 mm (0.79 in.)
B: 30 mm (1.18 in.)
C: 55 mm (2.17 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) Disconnect the manual valve connecting rod.
(d) Remove the valve body.
9. REMOVE 2ND BRAKE APPLY GASKET
HINT:
Replace the used gasket with a new one.