4WD TOYOTA TERCEL 1985 Repair Manual

PR-1
PROPELLER SHAFT
(for 4WDl
PRECAUTIONS
TROUBLESHOOTING
PROPELLER SHAFT
Page
PR.2
PR-2
PR.2
ril:t'
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FRONT AXLE AND SUSPENSION - Front Wheel AlignmentFA-3
FRONT WHEEL ALIGNMENT
1. MAKE FOLLOWING CHECKS AND CORRECT ANY
PROBLEMS
(d Check the tires for wear and proper inflation.
Cold tire inflation pressure kg/cm2(psi, kPa)
Tire sizeFront and Rear
FWD
145 SR 13
3A-C 4-speed M/T
Others
2.2 (32.220l.
2.O Q8,2001
155 SR 131.8(26. 180)
165 SR131 .8 (26, 180)
4WD155 SR 132.O Q8,2001
175 SR 131 .8 (26. 180)
(b) Check the front wheel bearings for looseness.
(d Check the wheel runout.
Lateral runout: 1.2 mm (0.047 in.) or less
(d) Check the front suspension for looseness.
(e) Check the steering linkage for looseness.
(f) Check that the front absorbers work properly by
using the standard bounce test.
ADJUST TOE.IN
Adjust toe-in with a toe-in gauge by the following pro-
cedure.
(d Check to see that both right and left tie rods measure
the same in length.
Left-right error: 1.5 mm (0.059 in.l or less
Move the vehicle forward a few meters with the front
wheels in the straight-ahead position on a level place.
Mark the center of each rear tread and measure the
distance between marks of the right and left tires.
(d) Advance the vehicle till the marks on the rear of the
tires come to the measuring heights of the gauge on
the front.
(e) Measure the distance between the marks on the front
of the tires.
Toe-in: lnspection STD -1 {- 1 mm(-0.O4 + O.O4 in.)
AA
+=ruf,ffi Wry@=S
--A-- F--B--i
A=B
2.
(b)
(c)
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FRONT AXLE AND SUSPENSION - Front Wheel AlignmentFA-5
Front Rear (FWDI
Rear (4WD)
More Camber
4, INSPECT VEHICLE HEIGHT
Vehicle heightmm (in.)
lf height of the vehicle is not within specification, try to
level it by shaking it down. lf the height is still not correct,
check for bad springs and worn or loose suspension parts.
5. ADJUST CAMBER camber:
VehicleInspection standardLeft-right error
FWDSedan10'+ 30'
30' or lessWagons' + 30'
4WD40' -t- 30'
lf camber is out of tolerance, adjust by turning the camber
adjusting cam.
(a) Loosen the shock absorber mount nut.
(b) Turn the cam to adjust.
NOTE: Camber changes about 20'with each graduation
of the cam.
(c) Tighten to the specified torque.
Torque: 1,45O kg-cm {105 ft-lb, 142 N'm)
6. ADJUST STEERING AXIS INCLINATION
VehicleInspection standardLeft-right error
FWDSedan12'30'* 30'
30' or lessWagon12035'+ 30'
4WD1 1'50' -t- 30'
lf the steering axis inclination is out of tolerance, inspect
and replace any damaged or worn front s$rplnsion parts.
s[
Tire sizeFrontRear
o
3
Sedan
145 SR 13
155 SR 13
165/70 SR 13
203.0 17.9921208.0 (8.189)
204.0 (8.O31)
287.O
292.O
288.0
1 1.299)
11.496)
1 1.339)
Wagor155SR13207 (8.150)308.512.146l.
4WD155 SR 13
t75/70 SR 13
234.419.2281
235.4 (9.268)273.O274.O
10.748)10.787)

FA.6FRONT AXLE AND SUSPENSION - Front Wheel Alignment
Front a-
Spacer
(o
7. ADJUSTCASTER
Caster
w/oPSw/ PS
o
3lt-
Inspection
Standard
Sedan1'10'+ 30'2"40' + 30'
Wagon0045' + 30'2"15' + 30'
Left-right error30' or less
o
3 Inspection standard2"25' -+- 30'
Left-right error30' or less
1'
lf the caster is not within specification, adjust by increas-
ing or decreasing the number of spacers. Do not install
more than two spacers.
Torque: 1,O75 kg-cm (78 ft-lb, 105 N.ml
NOTE: The caster will change 13' with each spacer.
ADJUST WHEEL ANGLE
Wheelangle
Inside wheelOutside wheel
o
=|'l-
Sedan
w/oPS
Max.36020' + 1032040' + 1"
at 2Oo21"30'200
w/ PSMax.35050' ! 1032'55'f 10
at 20o21"05'20"
Wagon
w/o PS
Max.36013' + 1032058'+ 10
at 2Oo21'25'20"
wi PSMax.35047'1 1'32050'= 1"
at 20"21"O9'20"
4WD
w/o PS
Max.36030' + 103301s'+ 10
at 2002'1"15'20"
w/ PSMax.36020'+ 1033020'+ 1'
at 2Oo21005'200
lf the steering angles differ from the standard specifica-
,'4o* tion, check to see that the length of the left and right tiet:ry rods are the same.
NOTE: lf the tie rod lengths are not equal, the steering
angle cannot be adjusted propedy.
lf the rie rod lengths were changed to adjust the steering
anble, reinspect the toe-in.
9. INSPECT SIDE SLIP WITH SIDE SLIP TESTER
Side slip: 3.O mm/m (O.118 in./3.3 ft) or less
lf the side slip is not within specification, the toe-in or
front wheel alignment may not be correct.
8.
\
--,-,-j:*-at-

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.
tr-;
W

I
FA-22 FRONT AXLE AND SUSPENSION - Front Shock Absorber
w/ PS and 4WD
3. INSTALL STEERING KNUCKTE TO SHOCK ABSORBER
(See step 4 on page FA-l1)
4. TOROUE SUSPENSIO\T SUPPORT NUT
Torque: 500 kg-cm (36 ft-|b,49 N.ml
5. INSTALL DUST COVER
Pack the bearing in the suspension support with MP
grease. Install the dust cover.
4ry.6.
cHEcK CAMBER (See page FA.sl
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RA.1
REAR AXLE AND
SUSPENSION
(FWD}
TROUBLESHOOTING
REAR WHEEL ALIGNMENT
REAR AXLE HUB AND CARRIER
Sedan
Wagon
REAR SUSPENSION
Rear Shock Absorber
Suspension Arm
Strut Rod
(4wD)
TROUBLESHOOTING
REAR AXLE SHAFT
DIFFERENTIAL
FOUR LINK TYPE REAR SUSPENSION
Coil Spring and Rear Shock Absorber
Lateral Control Rod
Upper and Lower Control Arm
Rear Stabilizer Bar
Page
RA-2
RA-3
RA.5
RA-5
RA-l2
RA.l6
RA.l7
RA.20
RA.23
RA.24
RA-25
RA.28
RA'42
RA.43
RA.46
RA-48
RA.s1

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