1985 TOYOTA TERCEL differential

REAR AXLE AND SUSPENSION - Differential (4WD)RA-33
3. IF NECESSARY, REPLACE SIDE BEARINGS
(a) Using SST, remove the side bearing from the
differential case.
ssT 09502-10012
NOTE: On the differential case there are indentations
into which the ssT fits.
(b) Using SST and a press, press in a new bearing.
ssr 09608-2001 1
4. INSPECT SIDE GEAR BACKLASH
Measure the side gear backlash while holding the other
side gear toward the case.
Standard backlash: 0.02 - 0.15 mm
(0.0008 - 0.0059 in.)
5. IF NECESSARY, REPLACE RING GEAR, SIDE GEARS
AND PINION GEARS
NOTE:
o lf the ring gear is to be used again, place matchmarks
before separating it.
o lf the ring gear or drive pinion are damaged, replace
them as a set.
(a) Lift the lock plates and remove the mount bolts.
(b) Using a plastic-faced hammer, tap on the ring gear to
separate it from the differential case.

RA.34REAR AXLE AND SUSPENSION - Differential (4WD)
(c) Using a pin punch and hammer, drive out the straight
pin foward the ring gear installation surface.
(d) Remove the pinion shaft, pinion gerars, side gears
and thrust washers.
te) Install the side gears, thrust washers, pinion gears
and shaft.
(f) Check the side gear backlash. (See page RA-33)
Standard backlash: O.O2 - 0.15 mm
(0.0008 - O.OO59 in.)
(g) lf the backlash is not within specification, use thrust
washer of a different thickness.
Thrust washer thickness mm (in.)
1.50 (0.0591) | r.65 (0.0650)
1 .s5 (0.061 0) | t .70 (0.0669)
1.60 (0.0630) | r.75 (0.0689)
(h) Using a pin punch and hammer, tap a new straight
pin through the case and hole in the pinion shaft.
(i) Stake the pin and differential case.
(j) Clean the contact surface of the differential case.
(0 Gradually heat the ring gear to about 1OO'C (212"F1
in an oil bath.
CAUTION: Do not heat the ring gear above 1lO'C
(230"F).
Ring Gear
=-_-
&

REAR AXIE AND SUSPENSION - Differential (4WD)RA-35
(l) Clean the contact surface of the ring gear with clean-
ing solvent.
(m) Then quickly install the ring gear on the differential
case.
(n) Coat the ring gear mount bolts with gear oil.
(o) Install new lock plates and the mount bolts. Tighten
the mount bolts uniformly and a little at a time. Tor-
que the bolts.
Torque: 985 kg-cm (71 ft-lb, 97 N.m)
(p) Check the ring gear runout.
Maximum runout: 0.07 mm (0.028 in.)
(q) Stake the lock plate.
NOTE: Stake one claw flush with the flat surface of the
nut. For the claw contacting the protruding portion of the
nut, stake (bend) only the half on the tightening side.
ASSEMBLY OF DIFFERENTIAL
(See page RA-28)
1. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) lnstall the following parts:
o Drive pinion
o Front bearing
NOTE: Assemble the spacer, oil slinger and oil seal after
adjusting the gear contact pattern.
(b) Using SST, install the companion flange.
ssT 09557-22022
(c) Adjust the drive pinion preload by tightening the
companion flange nut.
Using SST to hold the flange, tighten the nut.
ssT 09330-00020
CAUTION: As there is no spacer, taghten a little at a
time, being careful not to overtighten.

a
RA-36REAR AXLE AND SUSPENSION - Differential (4WD)
(d) Using a torque wrench, measure the preload.
Preload: New bearing 6.5 - 12.5 kg-cm
(5.6 - 1O.9 in.-lb)(0.6 - 1.2 N.ml
Reused bearing 4 - 7 kg-cm(3.5 - 6.1 in.-lb)(0.4 - 0.7 N.ml
2. INSTALL DIFFERENTIAL CASE IN CARRIER
(d Place the bearing outer races on their respective
bearings. Make sure the left and right outer races are
not interchanged.
(b) Install the case in the carrier.
3. INSTALL ADJUSTING NUTS
Install the adjusting nuts on their respective carrier, mak-
ing sure they are threaded properly.
NOTE: Make sure that there is backlash between the ring
gear and drive pinion.
4, INSTALL BEARING CAPS
Align the matcfimarks on the cap and carrier. Screw in the
two bearing cap bolts two or three turns and press down
the bearing cap by hand.
NOTE: lf the bearing cap does not fit tightly on the car-
rier, the adjusting nut threads are not threaded properly.
Reinstall adjusting nuts if necessary.
5. ADJUST SIDE BEARING PRELOAD
(a) Tighten the bearing cap bolts until the spring
washers are slightly compressed.
(b) Using SST, tighten the adjusting nut on the ring gear
side until the ring gear has a backlash of about 0.2
mm (0.0O8 in.).
ssr 09504-oool 1

REAR AXLE AND SUSPENSION - Differential (4WD)RA.37
(c) Using SST, firmly tighten the adjusting nut on the
drive pinion side.
ssr o9504-ooo1 1
(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

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.
ssr 09557-22022
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.
ssr 09330-ooo20
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.)