TOYOTA TERCEL 1985 Repair Manual

REAR AXLE AND SUSPENSION - Rear Suspension (FWD)RA-23
Strut Rod
(See page RA-l61
REMOVAL OF STRUT ROD
1. JACK UP VEHICLE (See page RA-2OI
2. REMOVE STRUT ROD
(a) Remove the bolt and nut holding the strut rod to the
axle carrier.
b) Remove the bolt and nut holding the strut rod to the
body and remove the strut rod.
INSTALLATION OF STRUT ROD
1. INSTALL STRUT ROD
(a) Connect the strut rod to the body with the bolt and
nut Do not torque the bolt yet.
NOTE: Be sure the lip of the nut is resting on the flange
of the bracket.
(b) Connect the strut rod to the axle carrier with the bolt
and nut. Do not torque the bolt yet.
NOTE: When connecting the strut rod, align the lip of
the nut with the groove on the bracket.
2. TOROUE STRUT ROD SETTING BOLTS
(a) Remove the stands and bounce the vehicle to stabil-
ize the suspension.
(b) Torque the setting bolts with the vehicle weight on
the suspension.
Torque: 890 kg-cm (64 ft-lb, 87 N'ml
3. CHECK REAR WHEEL ALIGNMENT (See page RA-31

RA.24REAR AXLE AND SUSPENSION - Troubleshooting (4WD)
TROUBLESHOOTING (4WD}
ProblemPossible causeRemedyPage
Oil leak at rear axleOil seals worn or damaged
Bearing retainer loose
Rear axle housing cracked
Replace oil seal
Replace retainer
Repair as necessary
RA-25
RA-25
Oil leak at pinion shaftOil level too high or wrong grade
Oil sealworn or damaged
Companion flange loose or damaged
Drain and replace oil
Replace oil seal
Tighten or replace flange
RA-28
RA-28
Noise in rear axleOil level low or wrong grade
Excessive backlash between drive pinion
and ring or side gear
Ring, drive pinion or side gears worn or
chipped
Drive pinion bearing worn
Axle shaft bearing worn
Side bearing loose or worn
Drain and replace oil
Check backlash
Check gears
Replace bearing
Replace bearing
Tighten or replace bearings
RA-28
RA-28
RA-28
RA.25
RA-36
BottomingVehicle overloaded
Shock absorber worn out
Springs weak
Check loading
Replace shock absorber
Replace spring
RA.43
RA.43

REAR AXLE AND SUSPENSION - Rear Axle Shaft (4WD)RA-25
WheelBrake Drum
Rear Axle Shaft
Bearing
[g-cm (tt-tu, trl'm)l : Tightening torque
<): Non-reusable part
YV?@ dmi
-r-/
oEnd Gasket | | | WBearins outer Retainer
O Retainer Casret | |Ilnner Retainerl
REAR AXLE SHAFT (4WD)
COMPONENTS
REMOVAL OF REAR AXLE SHAFT
1. REMOVE WHEEL AND BRAKE DRUM
2. REMOVE FOUR BACKING PLATE MOUNTING NUTS
REMOVE REAR AXLE
Using SST, pull out the rear axle.
ssr 09520-ooo31
CAUTION: When pulling out the rear axle, be careful
not to damage the oil seal.

RA-26REAR AXLE AND SUSPENSION - Rear Axte Shaft (4WD)
INSPECTION AND REPAIR OF REAR AXLE
SHAFT COMPONENTS
1. INSPECT REAR AXLE SHAFT AND FLANGE FOR
WEAR, DAMAGE OR RUNOUT
Maximum shaft runout: 1.5 mm {0.059 in.}
Maximum flange runout: 0.1 mm (0.0O4 in.)
lf the rear axle shaft or flange is damaged or worn, or if
their runout is greater than maximum, replace the rear axle
shaft.
INSPECT REAR AXLE BEARING FOR WEAR OR
DAMAGE
lf the bearing is damaged or worn, replace it.
REMOVE BEARING INNER RETAINER
(a) Using a grinder, grind down the inner retainer.
(b) Using a chisel and hammet cut off the retainer andremove it from the shaft.
REMOVE BEARING FROM SHAFT
Using SST, press the bearing off the shaft.
ssT 09527-2001 1
INSTALL BEARING OUTER RETAINER AND NEW
BEARING ON SHAFT
Using SST, press on the bearing outer retainer and new
bearing.
ssT 0951 5-20010
6. INSTALL BEARING INNER RETAINER ON SHAFT
(d Gradually heat the bearing inner retainer to about
150'C (302'F) in an oil bath.
2.
3.
150'c lnner Retainer

REAR AXLE AND SUSPENSION - Rear Axle Shaft (4WD)RA..27
(b) While the inner retainer is still hot, press the retainer
on the shaft with SST.
ssT 0951 5-20010
NOTE: Be sure that there is no oil or grease on the rear
axle shaft or retainer.
Face the non-beveled side of the inner retainer toward the
bearing.
7. INSPECT OIL SEAL FOR WEAR OR DAMAGE
lf the seal is damaged or worn, replace it.
8. REMOVE OIL SEAL FROM AXLE HOUSING
Using SST, remove the oil seal.
ssT 09308-00010
9. INSTALL NEW OIL SEAL IN AXLE HOUSING
(d Apply MP grease to the oil seal.
(b) Using SST, drive in the oil seal to a depth of 5.6 mm
(0.220 ini.
ssr 0951 7-12010
INSTALLATION OF REAR AXLE SHAFT
{See page RA-25}
1. APPIY LIOUID SEALEAR TO BOTH SIDES OF
END AND RETAINER GASKETS
2. PLACE NEW END AND RETAINER GASKETS IN
POSTTtON
Face the notch of the gasket downward.
3. INSTALL REAR AXLE SHAFT IN HOUSING
(a) Face the notch of the retainer downward.
(b) Install the rear axle shaft with four new self-locking
nuts.
Torque: 670 kg-cm (48 ft-tb, 66 N'm)
NOTE:
o Be careful not to damage the oil seal.
o When inserting the axle shaft, be careful not to hit or
dent the oil deflector inside the axle housing.
4. INSTALL BRAKE DRUM AND WHEEL
Drive in

RA.28REAR AXLE AND SUSPENSTON - Differentiat (4WD)
DIFFERENTIAL (4WD)
COMPONENTS
Pinion Shaft I
*:#ffi#6--
Pinion Gear
Differential Case
Oil Slinger
-rb, N.m)l : Tightening torque
O : Non-reusable part
Differential Carrier

REAR AXLE AND SUSPENSION - Differential (4WD)RA.29
SST
ON.VEHICLE REPLACEMENT OF OIL SEAL
1. DISCONNECT PROPELLER SHAFT FROM
DIFFERENTIAL (See page PR-3)
2. REMOVE COMPANION FLANGE(See step 7 on page RA-31)
3. REMOVE OIL SEAL AND OIL SLINGER
(d Using SST, remove the oil seal from the housing.
ssT 09308-10010
(b) Remove the oil slinger.
4. REMOVE FRONT BEARING AND BEARING SPACER(See step 9 on page RA-311
5. INSTALL NEW BEARING SPACER AND FRONT
BEARING (See step 9 on page RA-391
6. INSTALL OIL SLINGER AND NEW OIL SEAL
(a) lnstall the oil singer facing as shown.
(b) Using SST, drive in a new oil seal as shown.
ssr 09554-3001 1
Oil seal drive in depth: 1.0 mm (0.039 in.l
(c) Apply MP grease to the oil seal lip.
7, INSTALL COMPANION FLANGE(See step 11 on page RA-39)
8. ADJUST DRIVE PINION
(See step 12 on page RA-4OI
9. STAKE DRIVE PINION NUT
10. CONNECT PROPELLER SHAFT FLANGE TO
COMPANION FLANGE (See page PR-6)
1 1. CHECK DIFFERENTIAL OIL LEVEL
Fill with hypoid gear pil if necessary.
Oil grade: API GL-s hypoid gear oil
Viscosity: Above - 18'C (O"F) SAE 90
Below - 18'C (O"Fl SAE 8OW
or 8OW-90
Capacity: 1.O liters (1.1 US qts, 0.9 lmp. qts)
Torque the filler plug.
Torque: 500 kg-cm (36 ft-lb, 49 N.m)5 mm (O.20 in.)

RA.30REAR AXLE AND SUSPENSION - Differential {4WD)
REMOVAL OF DIFFERENTIAL
(See page RA-28)
1. DRAIN DIFFERENTIAL OIL
2. REMOVE REAR AXLE SHAFT (See page RA-25)
3. DISCONNECT PROPELLER SHAFT FROM
DIFFERENTIAL (See page RA-28)
4. REMOVE DIFFERENTIAL CARRIER ASSEMBLY
DISASSEMBLY OF DIFFERENTIAL
(See page RA-281
NOTE: lf the differential is noisy, perform the following
pre-inspection before disassembly to determine the cause.
lf the differential has severe problems, disassemble and
repair as necessary.
1. CHECK RING GEAR RUNOUT
Maximum runout: 0.07 mm (O.OO28 in.l
lf the runout is exceeds maximum, replace the ring gear.
2. CHECK RING GEAR BACKLASH
Backlash: 0.10 - 0.15 mm (O.OO39 - O.OO59 in.)
lf the backlash is not within specification, adjust the side
bearing preload or repair as necessary. (See step 5 on
page RA-36)
3, INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See step 6 on page RA-38)
Note the tooth contacting position.
4. CHECK SIDE GEAR BACKLASH
Measure the side gear backlash while holding one pinion
gear toward the case.
Standard backlash:
O.OZ - 0.15 mm (0.0008 - 0.0059 in.)
lf the backlash is not within specification, install the cor-
rect thrust washers.
5. CHECK DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the back-
lash between the drive pinion and ring gear.
Preload: 4-7 kg-cm
{3.5 - 6.1 in.-lb, 0.4 - O.7 N'm}
6. CHECK TOTAL PRELOAD
Using a torque wrench, measure the total preload.
Total preload:
In addition to drive pinion preload
2 - 4 kg-cm $.7 ' 3.5 in.-lb, O.2 - O.4 N'm)

REAR AXLE AND SUSPENSTON - Differentiat (4WD)RA-31
7. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, loosen the staked part of
the nut.
(b) Using SST to hold the flange, remove the nut and
washer.
ssT 09330-00020
b) Using SST, remove the companion flange.
ssT 09557-22022
8. REMOVE OIL SEAL AND OIL SLTNGER
h) Using SST, remove the oil seal from the housing.
ssr 09308-10010
(b) Remove the oil slinger.
9. REMOVE FRONT BEARING AND BEARING SPACER
(a) Using SST, remove the front bearing from the drivepinion.
ssT 09556-12010
(b) Remove the bearing spacer.
lf the front bearing is damaged or worn, replace the bear-ing.
10. REMOVE DIFFERENTIAL CASE FROM CARRIER
(d Put matchmarks on the bearing cap and differential
carrier.
(b) Remove the two adjusting nut locks.
(c) Remove the two bearing caps and two adjusting nuts.
(d) Remove the two bearing outer races.
(d Remove the differential case.

RA.32REAR AXLE AND SUSPENSION - Differential (4WD)
NOTE: Tag the disassembled parts to show the location
for reassembly.
11. REMOVE DRIVE PINION FROM DIFFERENTIAL
CARRIER
INSPECTION AND REPLACEMENT OF
DIFFERENTIAL
(See page RA-281
1. REPLACE DRIVE PINION REAR BEARING RACE
(a) Using SST and a press, pull out the rear bearing from
the drive pinion.
ssT 09950-00020
(b) Install the resued thrust washer on the drive pinion
with the chamfered end facing the pinion gear.
(c) Using SST and a press, press a new rear bearing on
the drive pinion.
ssT 09608-12010
REPLACE DRIVE PINION FRONT AND REAR BEARING
OUTER RACES
(a) Using a brass bar and hammer, tap out the outer
race.
(b) Using SST and a press, drive in a new outer race.
ssT 09608-1 201 0
RA0062
2.