Toyota Tercel 1984-1994 Repair Guide

Transaxle

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REMOVAL & INSTALLATION




CAUTION
On models equipped with a Supplemental Restraint System (SRS) or "air bag,'' work must NOT be started until at least 90 seconds have passed from the time that both the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery.

Wagons and 1984-1986 Sedans

See Figures 1, 2, 3, 4 and 5

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the radiator, then remove the upper radiator hose. Remove the air cleaner assembly.
  4.  
  5. Remove the transaxle upper attaching bolts.
  6.  
  7. Drain the fluid from the transaxle.
  8.  
  9. Remove both halfshafts. Refer to the procedure in this section.
  10.  



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Fig. Fig. 1: Transaxle upper attaching bolt locations



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Fig. Fig. 2: Pliers can be used to remove the clip retaining the shift control rod

  1. Remove the front exhaust pipe.
  2.  
  3. Disconnect the speedometer cable, then label and unplug all electrical connectors on the transaxle.
  4.  
  5. Disconnect the oil cooler inlet and outlet pipes, if equipped.
  6.  
  7. Disconnect the throttle valve linkage and the shift control rod.
  8.  
  9. On 4WD vehicles, remove the rear driveshaft.
  10.  
  11. Remove the torque converter cover, then remove the converter attaching bolts. Turn the crankshaft to gain access to each bolt.
  12.  
  13. Remove the transaxle lower attaching bolts.
  14.  
  15. Place a wooden block between the engine and cowl. This is done since the distributor may make contact with the brake booster when the rear support member is removed.
  16.  
  17. Support the transaxle with a jack, then remove the engine rear support member.
  18.  
  19. Separate the transaxle from the engine and carefully remove it from the vehicle.
  20.  

To install:
  1. Apply multi-purpose grease to the center hub of the torque converter.
  2.  



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Fig. Fig. 3: The torque converter bolts can be accessed after removing the cover



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Fig. Fig. 4: Transaxle lower attaching bolt locations

  1. Install a guide pin in the converter.
  2.  
  3. Position the transaxle for installation. Do not tilt the transaxle forward as the torque converter could slide out.
  4.  
  5. Align the guide pin with one of the drive plate holes. Connect the transaxle to the engine.
  6.  
  7. Install the transaxle lower attaching bolts. Torque the 10mm bolts to 29 ft. lbs. (39 Nm) and the 12mm bolts to 43 ft. lbs. (59 Nm).
  8.  
  9. Remove the guide pin, then install the rear support member. Torque the bolts to 70 ft. lbs. (95 Nm).
  10.  
  11. Install the torque converter mount bolts finger-tight. Uniformly torque the bolts to 13 ft. lbs. (18 Nm).
  12.  
  13. Install the converter cover and dust seal with the ground wire. Torque the 14mm bolt to 17 ft. lbs. (24 Nm) and the 17mm bolt to 48 inch lbs. (5.4 Nm).
  14.  
  15. On 4WD vehicles, install the rear driveshaft.
  16.  
  17. Connect the shift control rod and throttle linkage, then connect the oil cooler lines.
  18.  
  19. Install the front exhaust pipe and both halfshafts.
  20.  
  21. Install the transaxle upper attaching bolts. Torque the 14 mm bolts to 29 ft. lbs. (39 Nm) and the 17 mm bolts to 43 ft. lbs. (59 Nm).
  22.  
  23. Engage all electrical connectors on the transaxle.
  24.  
  25. Adjust the throttle linkage, then install the air cleaner.
  26.  



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Fig. Fig. 5: Support the transaxle with a jack before removing the rear crossmember

  1. Fill the transaxle with Dexron II® automatic transmission fluid.
  2.  
  3. Fill the front differential with GL-5 SAE 90 oil. Refer to Routine Maintenance for details.
  4.  
  5. Install the upper radiator hose and fill the cooling system. Connect the negative battery cable.
  6.  
  7. Adjust the throttle valve and shift linkages.
  8.  
  9. Road test the vehicle for proper operation. Recheck the fluid levels.
  10.  

1987-1994 Sedans

See Figures 6, 7, 8, 9, 10, 11, 12 and 13

  1. Disconnect the negative battery cable.
  2.  
  3. Unplug the electrical connections, then disconnect the speedometer cable.
  4.  
  5. Disconnect the throttle valve cable from the throttle linkage.
  6.  
  7. Remove the starter.
  8.  



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Fig. Fig. 6: Transaxle upper attaching bolt locations. Be sure to reconnect the ground wire when installing the transaxle



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Fig. Fig. 7: Remove the control cable retaining clip, then disconnect the cable from the control lever

  1. Remove the transaxle upper attaching bolts.
  2.  
  3. Remove the engine under cover, then disconnect the oil cooler lines.
  4.  
  5. Disconnect the shift control cable, then remove both halfshafts.
  6.  
  7. Remove the exhaust front pipe.
  8.  
  9. Remove the torque converter attaching bolts. Turn the crankshaft to gain access to each bolt.
  10.  



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Fig. Fig. 8: Make sure all electrical connections are disengaged before removing the transaxle

  1. Disconnect the left side engine mounting bracket. Hold the engine and transaxle with two jacks or a chain block and jack, then remove the rear engine mounting bracket. Remove the bolts attaching the bracket to the body first.
  2.  
  3. Remove the transaxle mounting bolts, then separate the transaxle from the engine. Have an assistant help you, the transaxle is a heavy component.
  4.  

To install:
  1. Position the transaxle for installation. Align the pins in the block with the converter housing. Temporarily install one bolt.
  2.  
  3. Install the transaxle attaching bolts. Torque the mounting bolts to 47 ft. lbs. (64 Nm).
  4.  
  5. Install the left side engine mounting bracket. Torque to 32 ft. lbs. (43 Nm).
  6.  
  7. Install the rear engine mounting bracket. Torque the engine bolts to 43 ft. lbs. (58 Nm) and the body bolts to 54 ft. lbs. (73 Nm).
  8.  
  9. Install the torque converter attaching bolts. Torque the bolts evenly to 13 ft. lbs. (18 Nm).
  10.  
  11. Install the front exhaust pipe.
  12.  
  13. Install the halfshafts.
  14.  



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Fig. Fig. 9: Remove the torque converter attaching bolts through the access hole



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Fig. Fig. 10: Secure both the engine and the transaxle with jacks



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Fig. Fig. 11: The left side mounting bracket is usually secured to the body by two bolts

  1. Connect the shift control cable, then install the oil cooler lines.
  2.  
  3. Install the engine under cover.
  4.  
  5. Install the upper transaxle attaching bolts.Torque the mounting bolts to 47 ft. lbs. (64 Nm).
  6.  
  7. Install the starter, then connect the throttle valve cable.
  8.  
  9. Connect the speedometer cable, then engage the electrical connectors.
  10.  
  11. Adjust the throttle valve and shift control cable.
  12.  
  13. Fill the transaxle and differential with Dexron II® automatic transmission fluid. Road test the vehicle for proper operation, then recheck the fluid levels. Refer to Routine Maintenance for details.
  14.  



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Fig. Fig. 12: Remove the bolts attaching the rear mounting bracket to the body first, then remove the bracket from the transaxle



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Fig. Fig. 13: Transaxle lower attaching bolt locations

 
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