1985 TOYOTA TERCEL Repair Manual

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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e_

I
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.
"1.

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
o@
g--ZA-r-a
/:A-F Suspension S upport
Ef
@-Dust Seat
@-sprinsseat
W
: Tightening torque
| : Non-reusable part
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.
tr-;
W

FRONT AXLE AND SUSPENSION - Front Shock AbsorberFA.21
INSPECTION OF FRONT SHOCK ABSORBER
INSPECT OPERATION OF SHOCK
(d Pull out the shock absorber piston rod at a constant
speed and check to see that the pull feeling
throughout the stroke is the same.
b) Check to see that there is no change in the pull when
the piston rod is rapidly moved up and down with a
stroke of 5 - 1O mm (0.20 - 0.39 in.).
ASSEMBLY AND INSTALLATION OF FRONT
SHOCK ABSORBER ASSEMBLY
(See page FA-l91
1. INSTALL BUMPER, COIL SPRING INSULATOR,
SPRING SEAT AND DUST SEAL
(d Mount the shock absorber in a vise.
(b) lnstall the bumber to the piston rod.
(c) Using SST, compress the coil spring.
ssT 09727 -22032
(d) Align the coil spring end with the lower seat hollow
and install.
(d Align the spring seat with the piston rod and install.
(fl lnstall the dust seal on the spring seat.
(g) Install the suspension support with a new nut. Do not
torque the nut yet.
2. INSTALL SHOCK ABSORBER TO BODY
Connect three bolts holding the shock absorber to the
body. Torque the nuts.
Torque: 24O kg-cm {17 ft-lb, 24 N.ml

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
l..:t
b!r

FRONT AXLE AND SUSPENSION - Front SuspensionFA-23
COMPONENTS
I 1,075 (78, los) |
a{Balljoint*-<-ry"
Bushing 7 S--t sro (5r, sot I
h
YooT.\€
ll-@
| | t(
I
cottar | |
I t BooCr, so-|l
l-lSpacer O
Fs-AmTliET'fri| : Tishtenins torque
l: Non-reugable part
Stabilizer Bar
FRONT SUSPENSION
Ball Joints
INSPECTION OF BALL JOINTS
1. INSPECT BALL JOINTS FOR EXCESSIVE LOOSENESS
(d Jack up the tront of the vehicle and place a wooden
block with a height of 18O - 2OO mm (7.09 - 7.87
in.) under one front tire.
(d Lower the jack until there is about half a load on the
front coil springs. Place stands under the vehicle for
safety.
(c) Make sure the front wheels are in a straightforward
position and block them with chocks.
(d) Move the lower arm up and down and check that the
balljoint has no excessive play.
Maximum balljoint vertical play: 0 mm (0 in.l
2. INSPECT BALL JOINT DUST COVERS FOR DAMAGE
OR DETERIORATION
lf a problem is found, replace the balljoint assembly.

'l
FA.24FRONT AXLE AND SUSPENSION - Front Suspension
\7
3. INSPECT BALL JOINT FOR ROTATION CONDITION
(d Remove the balljoint. (See page FA-29)
(b) As shown in the figure, flip the ball joint stud back
and forth 5 times before installing the nut
(d Using a torque gauge, turn the nut continuously one
turn each 2-4 seconds and take the torque reading
on the 5th turn.
Torque {turning}:
I - 25 kg-cm 17 - 21 in.-lb, 0.8 - 2'4 N'ml
lf the torque is not within specification, replace the ball
ioint.
Lower Arm
(See page FA-23)
REMOVAL OF LOWER ARM
1. DISCONNECT LOWER ARM TO STEERING KNUCKLE
Remove the two bolts holding the balljoint to the steering
knuckle.
2. DISCONNECT STABILIZER BAR END TO LOWER
ARM
Remove the stabilizer bar nut, retainer and cushion.
3. REMOVE LOWER ARM
(a) Jack up the opposite wheel until the vehicle body
lifts off the stands.
(b) Loosen the lower arm bolt, pry the lower arm and pull
out the bolt.
(d Disconnect the lower arm from the stabilizer bar.
CAUTTON: Be careful not to lose the caster adiust
spacer.
(d) Using SST, disconnect the ball joint from the lower
arm.
ssT 09950-2001 5
NOTE: Temporarily install the nut to prevent the balljoint
from falling out.