4WD TOYOTA TERCEL 1985 Owner's Manual

REAR AXLE AND SUSPENSION - Differential (4WD)RA.37
(c) Using SST, firmly tighten the adjusting nut on the
drive pinion side.
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(d) Check the ring gear backlash.
lf tightening the adjusting nut creates ring gear backlash,
loosen the nut so that backlash is eliminated.
(e) Place a dial indicator on the top of the bearing cap on
the ring gear side.
(f) Adjust the side bearing for zero preload by tightening
the other adjusting nut until the pointer on the indica-
tor begins to move.
(g) Tighten the adjusting nut 1 - 1llz notches from the
zero preload position.
(h) Using a dial indicator, adjust the ring gear backlash
until it is within specification.
Backlash: 0.10 - 0,15 mm (O.OO39 - O.OO59 in.l
NOTE: The backlash is adjusted by turning the left and
right adjusting nuts equal amounts. For example, loosen
the nut on the left side one notch and tighten the nut on
the right side one notch.
(i) Torque the bearing cap bolts.
Torque: 6OO kg-cm (43 ft-lb, 59 N.ml

RA.38REAR AXLE AND SUSPENSION - Differentiat (4WD)
(j) Recheck the ring gear backlash.
(0 Using a torque meter, measure the total preload.
Total preload:
ln addition to drive pinion preload
2 - 4 kg-cm 11.7 - 3.5 in.-lb, O.2 - 0.4 N.m)
Backlash: O.1O - O.15 mm (0.0039 - 0.O059 in.)
6. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Coat red lead on 3 or 4 teeth at three different posi-
tions of the ring gear.
(b) Hold the companion flange firmly and rotate the ring
gear in both directions.
(d lnspect the tooth pattern.
Heel ContactFace Contact
Select a thrust washer that wilt brinq thedrive pinion closer to the ring gear. -
,rfl
Select a thrust washer that will shift thedrive pinion away from the ring gear.

REAR AXLE AND SUSPENSION - Differential (4WD)RA.39
NOTE: lf adjusting the meshing of the teeth of the drive
pinion and ring gear by changing the extension of the drive
pinion, select a thrust washer of the appropriate thickness
from the table below.
REMOVE COMPANION FLANGE
(See step 7 on page RA-31)
REMOVE FRONT BEARING
(See step 9 on page RA-31)
INSTALL NEW BEARING SPACER AND FRONT
BEARING
(d lnstall a new bearing spacer on the shaft.
(b) lnstall the front bearing on the shaft.
10. INSTALL OIL SLINGER AND NEW OIL SEAL
(d Install the oil slinger facing as shown.
(b) Using SST, drive in a new oil seal as shown.
ssT 0951 7-12010
Oil seal drive in depth: 1.0 mm (0.039 in.)
(d Apply MP grease to the oil seal lip.
11. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange.
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7.
8.
9.
Drive in depth
Drive pinion thrust washer thickness mm (in.)
2.24 (O.O882) | Z.+8 (0.0976)
2.27 l}.O8e4l I Z.S1 (0.0988)
2.30 (0.0906) I Z.S4 (0.1000)
2.33 (0.0917) | 2.57 (0.1012)
2.36 (O.Os29) | Z.A0 {0.1024)
2.39 (0.0941) I 2.63 (0.103s)
2.42 (0.0953) | Z.A6 (0.1047)
2.45 (0.096s)

RA-/[()REAR AXLE AND SUSPENSION - Differential (4WD)
RAOO3
(b) Coat the threads of a new nut with MP grease.
(c) Using SST to hold the flange, tighten the nut.
Torque the nut.
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Torque: 1,425 kg-cm (103 ft-lb, 140 N'ml
12. ADJUST DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the back-
lash between the drive pinion and ring gear.
Preload: New bearing 6.5 - 12.5 kg-cm
(5.6 - 10.9 in.-lbl
(0.6 - 1.2 N'ml
Reused bearing 4 - 7 kg-cm
(3.5 - 6.1 in.-lbl
(0.4 - 0.7 N'ml
lf preload is exceeds specification, replace the bear-
ing spacer.
lf preload is less than specification, retighten the nut
130 kg-cm (9 ft-lb, 13 N.m) at a time until the
specified preload is reached.
lf the maximum torque is exceeded while retightening the
nut, replace the bearing spacer and repeat the preload pro-
cedure. Do not back off the pinion nut to reduce the
preload.
Maximum torque: 2,4OO kg-cm
(174 ft-lb, 235 N'm)
CHECK DEVIATION OF COMPANION FLANGE
Maximum tateral runout: 0.10 mm (0.0039 in.l
Maximum radial runout: 0.10 mm (0.0039 in.l
14. STAKE DRIVE PINION NUT
(a)
(b)
13.

REAR AXLE AND SUSPENSION - Differential (4WD)RA.41
15. INSTALL ADJUSTING NUT LOCKS
(a) Select either a lock plate No. 1 or No. 2 whichever
will fit the adjusting nuts.
(b) lnstall the lock plate on the bearing caps.
Torque: 55 kg-cm (48 in.-lb, 5.4 N'ml
INSTALLATION OF DIFFERENTIAL
(See page RA-281
1. INSTALL DIFFERENTIAL CARRIER ASSEMBLY
Install a new gasket and the differentialcarrier assembly in
the axle and install the twelve nuts. Torque the nuts.
Torque: 315 kg-cm (23 ft-lb, 31 N'm)
2. CONNECT PROPELLER SHAFT FLANGE TO
COMPANION FLANGE (See page PR-61
3. INSTALL REAR PLUG AND FILL DIFFERENTIAL WITH
GEAR OIL
Torque the drain plug.
Torque: 500 kg-cm (36 ft-|b,49 N'm)
Oil grade: API GL-s hypoid gear oil
Viscosity: Above - 18"C (O'Fl SAE 90
Below - 18'C (0"F) SAE 8OW
or 80W-90
Capacity: 1.0 liters (1.1 US qts, 0.9 lmp. qts)
Torque the filler plug.
Torque: 500 kg-cm (36 ft-|b,49 N'ml
5 mm (0.2O in.)

RA-42 REAR AXLE AND SUSPENSION - Four Link Type Rear Suspension (4WD)
FOUR LINK TYPE REAR SUSPENSION (4WDI
COMPONENTS
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Lower Control Arm
-lb, N'm)l : Tightening torque
Rear Stabilizer Bar

REAR AXLE AND SUSPENSION - Four Link Type Rear Suspension (4WD) RA-43
Coil Spring and Rear Shock Absorber
(See page RA-421
REMOVAL OF COIL SPRING AND SHOCK
ABSORBER
1. JACK UP VEHICLE
Jack up the rear axle housing and support the body with
stands. Leave the jack under the rear axle.
2. REMOVE REAR SHOCK ABSORBER
(a) Remove the bolt holding the shock absorber to the
rear axle housing and disconnect the shock absorber.
(d Remove the nuts holding the shock absorber to the
body, and remove the shock absorber.
3. REMOVE STABILIZER BAR BUSHING BRACKETS
Remove the bolts holding the stabilizer bar bushing to the
rear axle housing.
4. DISCONNECT LATERAL CONTROL ROD FROM REAR
AXLE HOUSING
Remove the nut holding the lateral control rod to the rear
axle housing and disconnect the lateral control rod.

RA-/14 REAR AXLE AND SUSPENSION - Four Link Type Rear Suspension (4WD)
5. REMOVE COIL SPRING
(a) Begin to lower the rear axle housing.
NOTE: Be careful not to pull the brake line and parking
brake cable.
(b) While lowering the rear axle housing, remove the coil
spring and the upper and lower insulators.
INSTALLATION OF COIL SPRING AND
SHOCK ABSORBER
1. PUT LOWER INSULATOR ON AXLE HOUSING
2, PUT UPPER INSULATOR ON COIL SPRING
3. INSTALL COIL SPRING
4. CHECK POSITION OF LOWER INSULATOR
(a) Jack up the rear axle housing.
(b) Check that the lower insulator is installed correctly.
lf the insulator is not in correct position, reinstall the
coil spring.

REAR AXLE AND SUSPENSION - Four Link Type Rear Suspension (4WD) Rl-+S
5. INSTALL LATERAL CONTROL ROD
In order, install a washer, bushing, spacer, lateral control
rod, bushing, washer and nut on the rear axle housing.
Do not tighten the nut yet.
6. INSTALL SHOCK ABSORBER
b) Connect the shock absorber to the body with the nut.
Hold the shaft with an adjustable wrench. Torque the
nut.
Torque: 250 kg-cm (18 ft-lb, 25 N.m)
(b) Connect the shock absorber to the rear axle housing
with the nut Torque the bolt.
Torque: 375 kg-cm (27 ft-\b,37 N.ml
7. INSTALL STABILIZER BAR BUSHING BRACKETS TO
REAR AXLE
8. STABILIZESUSPENSION
Remove the stands and bounce the car to stabilize the
suspension.

RA-/t6 REAR AXLE AND SUSPENSION - Four Link Type Rear Suspension (4WD)
9. TIGHTEN LATERAL CONTROL ROD NUT
h) Raise the axle housing until the body is free from the
stands.
(b) Torque the lateral control rod nut.
Torque: 650 kg-cm (47 ft-lb, 64 N'm)
Lateral Control Rod
(See page RA-421
REMOVAL OF LATERAL CONTROL ROD
1. SUPPORT REAR AXLE HOUSING
Jack up the rear axle housing and support it with stands.
2. DISCONNECT LATERAL CONTROL ROD FROM REAR
AXLE HOUSING
Remove the nut holding the lateral control rod to the rear
axle housing, and disconnect the lateral control rod.
3. DISCONNECT LATERAL CONTROL ROD FROM BODY
Remove the nut holding the lateral control rod to the body
and remove the lateral control rod.
REPLACEMENT OF LATERAL CONTROL ROD
BUSHING
1. REMOVE BUSHING
Using SST, press out the bushing from the lateral control
rod.
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NOTE: When inserting and removing the bushing, press
or pull from the chamfered side as shown in the figure.tRemove