1985 TOYOTA TERCEL Repair Manual

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.

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