TOYOTA TERCEL 1985 Repair Manual

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FRONT AXLE AND SUSPENSION - Axle HubFA-l1
3.3 -+
INSTALL HOLE SNAP RING
Using snap ring pliers, install the hole snap ring into the
steering knuckle.
INSTALL INNER OIL SEAL
Using SST, drive in a new bil seal.
ssT 09309-35010
NOTE: Tap in the oilseal3.3 -t- 0.1 mm (O.130 + 0.004
in.) from the end surface.
16. INSTALL DUST DEFLECTOR
Using SST, drive a new dust deflector into the steering
knuckle.
ssT o9316-60010
INSTALLATION OF FRONT AXLE HUB
(See page FA-7)
1. INSTALL AXLE HUB TO DRIVE SHAFT
lnstall the axle hub with the washer and lock nut. Do not
torque the nut yet.
CAUTION: Be careful not to damage the drive shaft
boot and oil seal lip.
14.
15.
2. INSTALL AXLE HUB TO LOWER ARM
Torque the*holding two bolts the steering 'knuckle to the
ilxb rower arm.
Torque: 82O kg-cm (59 ft-lb, 80 Nrml
3. INSTALL DISC TO
INSTALL STEERING KNUCKLE TO SHOCK ABSORBER
(a) Lower the stabilizer bar and assemble the steerirfi"
knuckle to the shock absorber lower bracket. :l;;
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FA..12FRONT AXLE AND SUSPENSION - Axle Hub
(b) lnsert the bolts from the front side and align the
matchmarks of the camber adjust cam.
(c) Torque the bolts.
Torque: 1,450 kg-cm (105 ft-lb, 142 N'ml
5. INSTALL BRAKE CALIPER TO STEERING KNUCKLE
Torque the bolts.
Torque: 970 kg-cm (70 ft-lb, 95 N.ml
#
6. CONNECT TIE ROD END TO STEERING KNUCKLE
Torque the nut and secure it with a new cotter pin.
Torque: 6O0 kg:cm (43 ft-lb, 59 N.m)
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TOROUE BEAfriG LOCK NUT AND INSTALL LOCK
NUT CAP AND;COTTER?IN
(a) Torqrle the lock nut wtrile depiUs.s.lng the brake pedal.
Torque: 1,900 kg-cm (137 ft-lb, f86 N.m)
(b) Install the lock nut cap affittsing plieib,.install a new
7.
cott*. pin.
8.
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CHECK FRONT WHEEL ALIGNMENT f$6e page FA-3)'-*+***n,. it'., . .i .:)".4..,,'i".: "
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FRONT AXLE AND SUSPENSION - Front Drive ShaftFA.13
FRONT DRIVE SHAFT
REMOVAL OF FRONT DRIVE SHAFT
Shock Absorber
Stiffener Plate(Left Side Only)
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Tie Rod End---€
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Disc Brake Caliper
1.900 {137, 186}Lower Arm
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1. REMOVE STEERING KNUCKE AND
AXLE HUB WITHOUT DISCONNECTING
LOWER ARM
(See step 1 to 6 and 8 on page FA-81
2. REMOVE FRONT DRIVE SHAFT
(a) Remove the stiffener plate from the transaxle as-
sembly and"engine (left side only).
(b) Using SST.and a hammer, tap out the front drive
shaft.
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1FA.l4FRONT AXLE AND SUSPENSION - Front Drive Shaft
(d After pulling out the shaft, leave the SST inserted.
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DISASSEMBLY OF FRONT DRIVE SHAFT
1. REMOVE SNAP R|NG FROM TNBOARD'OITI
2. CHECK DRIVE SHAFT ,-
(a) Check to see that there jS.po play in the outboard
joint. ' :*
(b) Check to see that 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.
(d Check for damage to the boot.
3. DISASSEMBLE BOOT CLAMPS
COMPONENTS
Dynamic Damper (LH Shaft Only)
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Drive Shaft (with Outboard Joint)
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Inboard Joint Shaft
Tripod
Boot
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FRONT AXLE AND SUSPENSION - Front Drive ShaftFA-l5
4. DISASSEMBLE INBOARD JOINT SHAFT
(d Place matchmarks on the inboard joint shaft and
drive shaft.
CAUTION: Do not use a punch.
(b) Remove the inboard joint from the drive shaft.
5. DISASSEMBLE TRIPOD JOINT
{a) Using snap ring pliers, remove the snap ring.
(d Using a punch and hammer place matchmarks on the
shaft and tripod.
(d Uniformily tap to remove the tripod joint from the
drive shaft.
CAUTION: Do not tap on the roller.
6. REMOVE FOLLOWING PARTS:
(a) Remove the boot from the drive shaft
(b) Remove the clamp and dynamic damper (LH shaft
only.)
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(c) Remove the two boot clamps from the boot of the
outboard joint.
(d) Remove the boot from the outboard joint.
CAUTION: Do not remove the outboard joint.
(e) Check the inside and outside of the boot for damage.
Do not remove.
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FA-l6FRONT AXLE AND SUSPENSION - Front Drive Shaft
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406 mm r(15.98 in.) |
ASSEMBLY OF FRONT DRIVE SHAFT
(See page FA-l41
1. PROVISIONALLY INSTALL BOOT AND BOOT CLAMP
TO OUTBOARD JOINT
NOTE: Before installing the boot wrap vinyltape around
the spline of the shaft to prevent damaging the boot.
INSTALL DYNAMIC DAMPER AND CLAMP
(LH SHAFT onlyl
PROVISIONALLY INSTALL BOOT AND CLAMP(For INBOARD JOINTI TO DRIVE SHAFT
ASSEMBLE BOOT CLAMPS ONTO DRIVE SHAFT
ASSEMBLE TRIPOD JOINT
(a) Place the beveled side of the tripod axial spline
toward the outboard joint.
(b) Align the matchmarks placed before disassembly.
When replacing the inboard joint, first align the
center of the inboard joint and outboard joint.
Using a brass bar and hammer, tap the tripod onto
the drive shaft.
2.
3.
4.
5.
(c)
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FRONT AXLE AND SUSPENSION - Front Drive ShaftFA-l7
6. INSTALL NEW SNAP RING
Using snap ring pliers, install a new snap ring.
7. ASSEMBLE BOOT TO OUTBOARD JOINT SHAFT
Before assembling the boot pack in 24O g (0.5 lb) of
grease.
NOTE: Use the grease supplied in the boot kit.
8. ASSEMBLE INBOARD JOINT TO DRIVE SHAFT
(a) Pack in 140 g (0.3 lb, 1 .4 N) of grease.
Amount: Joint side 90 g {0.2 lOl
Boot side 50 g (0.1 lul
NOTE: Use the grease supplied in the boot kit.
(b) Align the matchmarks placed before disassembly.
(c) lnstall the inboard joint shaft to the drive shaft.
(d) lnstall.lF Uoo, to the inboard joint shaft.
9. ASSEMBLE BOOTS CLAMP TO BOTH BOOTS
(d Be sure the boot is on the shaft groove.
(b) Install a new 4amp on the inboard joint side around
the hollow pffin of the cover.
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FA-l8FRONT AXLE AND SUSPENSION - Front Drive Shaft
Length
(c) Bend the clamp and lock it as is shown in the figure.
(d) Check that the boot is not stretched or contracted
when the drive shaft is at specified length.
Drive shaft length:
Right side Approx. 620 mm 124.41 in.l
Left side Approx. 722 mm (28,43 in.)
10. INSTALL NEW SNAP RING TO INBOARD JOINT
SHAFT
INSTALLATION OF FRONT DRIVE SHAFT
(See page FA-l3)
1. INSTALL DRIVE SHAFT TO TRANSAXLE ASSEMBLY
(a) Apply MP grease to the oil seal lip.
(b) lnstall the drive shaft by tapping on the SST.
ssT 09648-16010
NOTE: Whether or not the drive shaft is contacting the
pinion shaft can be know by its sound or feel when tap-
ping it in.
INSTALL STIFFENER PLATE
lnstall the three bolts holding the stiffener plate to the
engine and transaxle. Torque the bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N'm)
INSTALL STEERING KNUCKE AND AXLE HUB
(See step 2 to 7 on page FA-l1 and 12)
4. CHECK FOLLOWING PARTS:
(d Check the boots for damage.
NOTE: Check the entire circumference of the boots.
(b) Check the length between the left and right shaft
after installinq,.the drive shaft.i": ' -|*itLength: Approjff{93 mm (7.60 in.)
5. CHECK FRONT"WHEEL ALIGNMENT (See page FA-31
2.
3.
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FRONT AXLE AND SUSPENSION - Front Shock AbsorberFA-l9
FRONT SHOCK ABSORBER
COMPONENTS
REMOVAL DISASSEMBLY OF FRONT SHOCK
ABSORBER ASSEMBLY
1. DISCONNECT STEERING KNUCKLE FROM SHOCK
ABSORBER (See step 6 on page FA-81
2. REMOVE SHOCK ABSORBER ASSEMBLY FROM
BODY ii.
(d Remove the dust cover from the suspqnsion support.
(b) Loosen the nut. Do not remove the nut yH"
$-Dust Cover
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@-Dust Seat
@-sprinsseat
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CoilSpring
(ft-lb. N.m)

FA-20FRONT AXLE AND SUSPENSION - Front Shock Absorber
w/o PS
w/ PS and 4WD
(c) Remove the three nuts holding the shock absorber to
the body.
(d Remove the shock absorber assembly.
CAUTION: Cover the drive shaft boot with cloth to
avoid damage.
3. CLAMP SHOCK ABSORBER IN VISE
Install a bolt and nuts to the bracket at the lower portion of
the shock absorber shell and secure it in a vise.
4, REMOVE COIL SPRING
(d Using SST, compress the coil spring.
ssr 09727 -22032
(b) Hold the suspension with a screwdriver or such so
that it will not turn, and then remove the support nut.
(c) Remove the suspension support, spring seat, spring
and dust cover.
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