Transaxle TOYOTA TERCEL 1996 Service Repair Manual

IN04Q-07
- INTRODUCTIONTERMS
IN-31
31 Author
: Date
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1996 TERCEL (RM440U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti-Lock Brake System
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir-Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi-Level
B/SBore-Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
Calif.California
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve

- INTRODUCTIONTERMS
IN-33
33 Author
: Date
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1996 TERCEL (RM440U) H/B
Hatchback
H-FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HPUHydraulic Power Unit
HSGHousing
HTHard Top
HWSHeated Windshield System
IACIdle Air Control
ICIntegrated circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
J/BJunction Block
J/CJunction Connector
KDKick-Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft-Hand
LHDLeft-Hand Drive
L/H/WLength, Height, Width
LLCLong-Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAX.Maximum
M-FUSEMedium Current Fuse
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPXMultiplex Communication System
M/TManual Transmission (Transaxle)
MTMount
MTGMounting
NNeutral

IN-34
- INTRODUCTIONTERMS
34 Author
: Date
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1996 TERCEL (RM440U) NA
Natural Aspiration
No.Number
O/DOverdrive
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PSPower Steering
PTOPower Take-Of f
R & PRack And Pinion
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight-Hand
RHDRight-Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRRear-Engine Rear-Wheel Drive
RRSRigid Rear Suspension
RWDRear-Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SMTSequential Manual Transmission
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold-Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection

P21589
SA3501
Grease
RA0489
MA-8
- MAINTENANCECHASSIS
46 Author
: Date
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1996 TERCEL (RM440U)
(b) Check the dust cover for damage.
6. CHECK TRANSAXLE OIL (FLUID)
Visually check the transaxle for oil (fluid) leakage.
If leakage is found, check for the cause and repair.
7. REPLACE TRANSAXLE OIL (FLUID)
(a) M/T:
Replace the transaxle oil (See page MX-6).
(b) A/T:
Replace the transaxle fluid.
(A132L: See page AX-2)
(A242L: See page AX-2)
8. REPACK REAR WHEEL BEARINGS
(a) Change rear wheel bearing grease.
(1) Remove the hub and inner and outer bearings.
Clean in solvent and inspect the bearings for dam-
age.
(2) Pack the bearings and axle hubs with multipurpose
grease.
Wheel bearing grease grade:
Lithium base multipurpose grease (NLGI No.2)
(b) Install inner bearing and new oil seal.
(c) Install the hub and adjust the wheel bearing preload (See
page SA-42).
Preload (while turning):
Add frictional force plus
0 - 11.8 N (0 - 1.2 kgf, 0 - 2.6 lbf)

PP3IW-01
- PREPARATIONMANUAL TRANSAXLE
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1996 TERCEL (RM440U)
MANUAL TRANSAXLE
SST (Special Service Tools)
09201-10000Valve Guide Bushing Remover &
Replacer SetSpeedometer driven gear oil seal
(09201-01080)Valve Guide Bushing Remover &
Replacer 8
09308-00010Oil Seal PullerOutput shaft front bearing
09309-120205th Driven Gear Replacer
09350-32014TOYOTA Automatic Transmission
Tool Set
(09351-32090)Oil Seal Remover & ReplacerDifferential side bearing
(09351-321 11)Side Bearing Race ReplacerDifferential side bearing oil seal
(Transmission case side)
(09351-32120)Overdrive Bearing ReplacerDifferential side bearing
(09351-32130)Handle
(09351-32150)Oil Seal ReplacerDifferential side bearing oil seal
(Transaxle case side)
09564-3201 1Differential Preload Adaptor
09608-00071Drive Pinion Rear Bearing Cone
ReplacerInput shaft rear ball bearing
4th driven gear and rear ball bearing

PP-36
- PREPARATIONMANUAL TRANSAXLE
83 Author
: Date
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1996 TERCEL (RM440U)
09612-2201 1Tilt Handle Bearing ReplacerNo. 3 hub sleeve assembly
09612-65014Steering Worm Bearing PullerInput shaft front bearing and oil seal
Differential taper roller bearing outer
race
09921-00010Spring Tension ToolSpeedometer driven gear oil seal
09950-00020Bearing Remover
09950-00030Bearing Remover Attachment
09950-4001 1Puller B Set
09950-60010Replacer Set
(09951-00360)Replacer 36Input shaft front oil seal
Differential case side bearing
(09951-00460)Replacer 46Input shaft front bearing
(09951-00620)Replacer 62Output shaft front bearing
09950-60020Replacer Set No.2
(09951-00680)Replacer 68Differential taper roller bearing outer
race (Transaxle case side)
(09951-00710)Replacer 71Differential taper roller bearing outer
race (Transmission case side)

- PREPARATIONMANUAL TRANSAXLE
PP-37
84 Author
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1996 TERCEL (RM440U)
09950-70010Handle Set
(09951-07150)Handle 150

PP3IV-01
PP-38
- PREPARATIONMANUAL TRANSAXLE
1996 TERCEL (RM440U)
RECOMMENDED TOOLS
09025-00010Torque Wrench (30 kgf-cm)Differential preload
09031-00030Pin Punch .
09040-0001 1Hexagon Wrench Set .
09905-00012Snap Ring No.1 Expander .

PP14S-01
- PREPARATIONMANUAL TRANSAXLE
PP-39
1996 TERCEL (RM440U)
EQUIPMENT
Dial indicator with magnetic base
Feeler gauge
Magnetic finger
Micrometer
Torque wrench

PP14T-01
PP-40
- PREPARATIONMANUAL TRANSAXLE
1996 TERCEL (RM440U)
LUBRICANT
ItemCapacityClassification
Manual transaxle oil (w/ Differential oil)1.9 liters (2.0 US qts, 1.7 lmp. qts)API GL-4 or GL-5
SAE 75W-90