Tercel 1995-1996

Transaxle Removal & Installation

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  1. Disconnect the negative battery cable, then the positive. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  
  3. Remove the battery.
  4.  
  5. Remove the air cleaner case assembly with the air hose.
  6.  
  7. Remove the clutch release cylinder and tube clamp.
  8.  
  9. Remove the two bolts and ground cable from the transaxle side and engine left mounting bracket side.
  10.  
  11. Disconnect the back-up light switch electrical connector.
  12.  
  13. Remove the clips and washers that connect the shifter control cables to the transaxle.
  14.  
  15. Remove the retainers that attach the shifter control cables to the transaxle and position the cables out of the way.
  16.  
  17. Remove the upper transaxle attaching bolts.
  18.  
  19. Safely raise and support the vehicle.
  20.  
  21. Remove the front wheels.
  22.  
  23. Remove the engine undercovers, if equipped.
  24.  
  25. Drain the oil from the transaxle.
  26.  
  27. Remove the left and right halfshafts.
  28.  
  29. Remove the front exhaust pipe, if necessary.
  30.  
  31. Disconnect the speedometer cable from the transaxle.
  32.  
  33. Remove the starter electrical connectors and mounting bolts. Remove the starter from the engine.
  34.  
  35. Remove the rear engine mounting insulator and bracket.
  36.  
  37. Using a block of wood and a floor jack, place it under the engine's oil pan and support it.
  38.  
  39. Using a floor jack, position it under the transaxle and support its weight.
  40.  
  41. Remove the left engine mount.
  42.  
  43. Remove the transaxle attachment bolts from the engine.
  44.  
  45. Lower the left side of the engine and remove the transaxle from the vehicle.
  46.  

To install:

  1. Align the input shaft spline with the clutch disc and install the transaxle to the engine. Install the transaxle attaching bolts and torque the bolts to specification.

    Click image to see an enlarged view

    Fig. Torque the transaxle mounting bolts to specification-Tercel

  2.  
  3. Install the left engine mounting bracket with the two bolts. Torque the bolts to 36 ft. lbs. (48 Nm).
  4.  
  5. Install the rear mounting insulator with the six bolts. Torque the bolts as follows:

    A-Body side bolt through brackets to 58 ft. lbs. (78 Nm)
     
    B-Through bolt to 47 ft. lbs. (64 Nm)
     
    C-Body side bolt though insulator to 67 ft. lbs. (90 Nm)
     

  6.  
  7. Remove the jacks from under the transaxle and engine.
  8.  
  9. Install the starter and electrical connectors. Torque the starter bolts to 29 ft. lbs. (39 Nm).
  10.  
  11. Connect the speedometer to the transaxle.
  12.  
  13. Install the front exhaust pipe, if removed.
  14.  
  15. Install the right and left halfshafts.
  16.  
  17. Fill the transaxle with 75W-90 or 80W-90 gear oil.
  18.  
  19. Install the undercovers, if removed.
  20.  
  21. Install the wheels.
  22.  
  23. Lower the vehicle.
  24.  
  25. Position the shift control cables and install the retainers, the washers and the clips.
  26.  
  27. Connect the back-up light switch electrical connector.
  28.  
  29. Install the clutch release cylinder and tube clamp.
  30.  
  31. Install the air cleaner assembly with the air hose.
  32.  
  33. Connect the two ground cable to the transaxle.
  34.  
  35. Install the battery.
  36.  
  37. Road test the vehicle.
  38.  

 
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