Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Celica 1988-1989.1993-1994.2000 Approved Toyota Celica 1989 drive axle 4wd models with integral housing
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DRIVE AXLE - 4WD MODELS WITH INTEGRAL HOUSING
1988 Toyota Celica
DRIVE AXLES
Toyota Integral Housing
Celica (Rear)
DESCRIPTION
Drive axle assembly is hypoid type with integral carrier
housing.
AXLE RATIO & IDENTIFICATION
Integral carrier type drive axle may be identified by
inspection cover on rear of carrier housing. To determine axle ratio,
divide number of ring gear teeth by number of pinion gear teeth.
REMOVAL & INSTALLATION
AXLE SHAFTS & BEARINGS
See FWD AXLE SHAFTS or RWD AXLE SHAFTS article in this
section.
DRIVE PINION FLANGE & OIL SEAL
Removal
1) Index drive shaft to drive pinion flange. Remove drive
shaft. Remove rear crossmember. Loosen staked portion of drive pinion
flange nut. Remove drive pinion flange nut.
2) Remove drive pinion flange. Remove oil seal from
housing. Remove oil slinger. Using a puller, remove front bearing
from housing. Remove collapsible spacer and discard.
NOTE: Toyota recommends replacing collapsible spacer anytime
pinion flange is loosen or removed.
Installation
1) Install new collapsible spacer and front bearing. Install
oil slinger with concave side facing front drive pinion bearing. Apply
grease to seal lips. Install new oil seal to correct depth. See SEAL
DEPTH table at end of this article. Install flange and lightly coat
drive pinion threads with grease.
2) Install flange nut and hold flange. Tighten nut and
measure preload. See TIGHTENING SPECIFICATIONS table and AXLE
ASSEMBLY SPECIFICATIONS table at end of this article. If preload is
lower than specification, tighten nut in increments of 108 INCH lbs.
(12 N.m) until preload is correct. Check pinion nut torque.
3) Check longitudinal and latitudinal runout of drive pinion
flange with dial indicator. Stake drive pinion nut. Install drive
shaft. Ensure index marks are aligned.
DIFFERENTIAL ASSEMBLY
Removal
1) Drain gear oil. Remove rear crossmember. Disconnect drive
axles from side gear flanges. Index drive shaft to drive pinion
flange. Disconnect drive shaft. Remove nuts from differential
assembly-to-support bolts.
2) Support differential assembly with jack. Remove through
bolts holding small support member (on differential case) to large
support member. Remove bolts holding case to chassis crossmember.
Lower differential carrier from vehicle.
Installation (All Models)
To install, reverse removal procedure. Align index marks on
drive shaft and drive pinion flange.
Fig. 1: Exploded View of Differential Assembly
Courtesy of Toyota Motor Sales, U.S.A., Inc.
OVERHAUL
DISASSEMBLY
NOTE: For overhaul information on front drive axles, see FWD AXLE
SHAFTS article in this section. On rear drive axles, see RWD
AXLE SHAFTS article in this section.
Differential Case (Conventional)
1) Remove differential carrier cover. Remove side gear shaft
and oil seal. Check ring gear runout and backlash. Check gear tooth
contact pattern. Check side gear backlash while holding one pinion
gear toward case. Measure drive pinion preload and total preload.
2) Put alignment marks on bearing cap and differential
carrier. Remove caps. Remove 2 side bearing preload adjusting plate
washers. Measure plate washers and record thicknesses. Remove
differential case and ring gear. Remove differential case side
bearing outer races. Place reference marks on bearings, gears and
thrust washers.
3) Remove side bearings from case with puller. Keep side
bearings with correct outer races and mark for reassembly. Put
alignment marks on ring gear and differential case. Remove ring gear
bolts and locking tabs. Remove ring gear by tapping on gear with a
plastic hammer.
Drive Pinion
1) Hold drive pinion flange and remove nut. Remove drive
pinion flange and oil seal. Remove oil slinger, front bearing and
collapsible spacer. Remove drive pinion from differential carrier.
Press rear bearing from pinion shaft.
2) Drive front and rear drive pinion bearing outer races
from carrier. Inspect bearings, outer races and pinion shaft for wear
or damage. Discard collapsible spacer. Ring gear and drive pinion
must be replaced as a set.
Fig. 2: Exploded View of Differential Assembly (Cessida)
Courtesy of Toyota Motor Sales, U.S.A., Inc.
REASSEMBLY & ADJUSTMENT
Differential Case (Conventional)
1) Install side gears and thrust washers in case. Thrust
washers should be same size for both sides if possible. Install pinion
gears with thrust washers and tap pinion shaft into place. Check side
gear backlash while holding one pinion gear toward case.
2) If backlash is incorrect, change thickness of thrust
washers until backlash is within range of .002-.008" (.05-.20 mm).
Install lock pin through case and hole in pinion shaft. Stake pin to
differential case. Press side bearings onto case.
3) Clean contact surfaces of differential case. Heat ring
gear to 212 F (100 C) in oil bath. Clean ring gear contact surface
with solvent. Install on case while still hot. Align index marks on
ring gear and case. Coat ring gear bolts with hypoid oil and install
with lock plates.
CAUTION: Do not heat ring gear above 230 F (110 C).
4) Tighten ring gear bolts gradually in diagonal sequence.
When bolts are snug, tighten to 71 ft. lbs. (97 N.m). Stake lock
plates with one tab flush against flat of bolt head. Tab resting on
point should be staked on tightening side of point.
5) Install case with side bearings into carrier. Snug down
adjusting nut until there is no play in bearing. Check ring gear
runout with a dial indicator against back of gear (opposite teeth) in
4 places.
6) Maximum allowable runout is .003" (.07 mm). If runout is
excessive, rotate ring gear on case and remeasure. If runout cannot
be brought within specified range, case or ring gear must be replaced.
Drive Pinion Bearing Preload
1) Install front and rear bearing outer races into carrier.
Press rear drive pinion bearing onto drive pinion with depth shim
under bearing. Install drive pinion into carrier. Install front
bearing.
NOTE: Drive pinion preload is set in 2 stages. Initial adjustment
is made without spacer, oil slinger or oil seal installed.
Final adjustment is made after differential case is
installed and ring and pinion backlash have been set.
2) Install drive pinion flange and lightly grease threads of
pinion flange nut. Install flange nut and adjust drive pinion preload
by slowly tightening nut. Measure preload with torque wrench. See
AXLE ASSEMBLY SPECIFICATIONS table at end of article..
CAUTION: As there is no spacer installed at this time, tighten
pinion nut slowly until desired preload is obtained. Be
careful not to overtighten.
3) Install differential case and adjust ring gear-to-drive
pinion backlash. See RING GEAR BACKLASH & SIDE BEARING PRELOAD
procedure in this article. Remove drive pinion flange and front
bearing. Install new bearing spacer, front bearing, oil slinger, and
oil seal. Install drive pinion flange and tighten pinion nut.
4) Check total differential preload. Range for total preload
is measured drive pinion preload plus 2.6-4.3 INCH lbs. (.29-.49 N.m)
(.40-.59 N.m). Check that drive pinion flange longitudinal and
latitudinal runout do not exceed .004" (.10 mm). Stake drive pinion
nut.
Ring Gear Backlash & Side Bearing Preload
1) Place bearing outer races on respective bearings and
install differential case into carrier. Install plate washer only on
back side of ring gear (behind teeth). Tap ring gear with plastic
hammer to seat washer and bearing.
2) Install a dial indicator with plunger on tooth surface of
ring gear. Apply downward pressure on side bearing boss. Measure ring
gear-to-drive pinion backlash. Reference backlash should be .005" (.13
mm) on all models.
3) Select a ring gear (back side) plate washer using
backlash as reference. Select a ring gear (tooth side) washer just
thick enough to eliminate clearance between outer race and case.
Remove plate washers and case from carrier.
4) Install plate washer into lower part of carrier. Place
other plate washer on differential case with outer race. Install case
assembly into carrier housing. Seat washer and bearing by tapping
ring gear with plastic hammer. Measure ring gear backlash with dial
indicator.
5) Backlash should be .005-.007" (.13-.18 mm). Adjust
backlash by increasing or decreasing washers on both sides by equal
amounts. There should be no clearance between plate washer and case.
Ring gear backlash must exist at all times.
6) After adjustment of plate washers has been made, remove
ring gear (tooth side) washer and measure thickness. Install washer
.002-.004" (.05-.10 mm) thicker than washer removed.
NOTE: Select washer which can be pressed 2/3 of way in by finger.
7) Using a plastic hammer, tap washer in place. Recheck ring
gear backlash. Backlash range is .005-.007" (.13-.18 mm). Adjust as
necessary. Align index marks on caps and carrier. Install cap bolts
and tighten to 58 ft. lbs. (78 N.m).
8) Measure total preload. Total preload must equal drive
pinion preload plus 2.6-4.3 INCH lbs. (.29-.49 N.m)
9) Hold companion flange firmly and rotate ring gear in both
directions. Inspect gear tooth contact pattern. Adjust as necessary
by changing shims on drive pinion. See GEAR TOOTH PATTERNS article in
this section.
10) Drive side gear shaft oil seal into carrier until flush.
Coat oil seal lips with grease and replace snap ring on side gear
shaft. Drive side gear shaft in until it contacts pinion shaft.
Measure side gear runout at flange with dial indicator. Replace side
gear shaft if runout exceeds .008" (.20 mm). Install differential
carrier cover with new gasket and tighten bolts.
NOTE: Since shaft cannot be checked visually on LSD models, ensure
that shaft is seated by change in sound made by hammer blow
after shaft bottoms out.
AXLE ASSEMBLY SPECIFICATIONS TABLE
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