Toyota Tercel 1984-1994 Repair Guide

Lower Ball Joint

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INSPECTION



See Figure 1

Vertical Play
Performed on 1984-90 models
  1. Raise the front of the vehicle, then place a wooden block with a height of 7.09-7.87 in. (180-200mm) under the tire of the side to be checked.
  2.  
  3. Lower the jack until there is about half a load on the front coil springs. Place the stands under the vehicle for safety.
  4.  
  5. Make sure the front wheels are in a straight-forward position, then block them with chocks.
  6.  
  7. Move the lower arm up and down and check that there is no vertical play.
  8.  
  9. If vertical play is found, replace the ball joint.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Checking the ball joint vertical play

Turning Torque

See Figure 2

Performed on 1984-94 models
  1. Remove the ball joint. Refer to the procedures in this section.
  2.  
  3. Move the ball joint stud back and forth five times, then thread a nut onto the stud.
  4.  
  5. Using a torque wrench, turn the nut slowly and continuously (each turn should take between 2-4 seconds). On the fifth turn, take a torque reading.
  6.  
  7. The turning torque on 1984-90 models should be between 6.9-21.7 inch lbs. (0.8-2.5 Nm). A reading between 8.7-26 inch lbs. (1-2.9 Nm) should be found on 1991-94 models.
  8.  
  9. Replace the ball joint, if necessary.
  10.  



Click image to see an enlarged view

Fig. Fig. 2: Move the ball joint stud back and forth several times, then check the turning torque

REMOVAL & INSTALLATION



See Figures 3 and 4


CAUTION
On models equipped with a Supplemental Restraint System (SRS) or "air bag,'' work must NOT be started until at least 90 seconds have passed from the time that both the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery.


CAUTION
The suspension on any vehicle is assembled with high grade, hardened fasteners. NEVER substitute a fastener of inferior load rating when assembling a suspension component!

The use of the special tools is required for this procedure. A ball joint separator is a commonly available tool which prevents damage to the joint and knuckle. Do not attempt to separate the joint with hammers, prybars or similar tools.

Wagons and 1984-86 Sedans
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the front of the vehicle with jackstands.
  4.  
  5. Remove the nuts/bolts attaching the lower ball joint to the steering knuckle.
  6.  
  7. Remove the cotter pin and nut from the ball joint stud.
  8.  
  9. Use SST 09950-20016 or its equivalent to press the ball joint out of the control arm.
  10.  



Click image to see an enlarged view

Fig. Fig. 3: A special tool is used to remove the ball joint



Click image to see an enlarged view

Fig. Fig. 4: On some models, it is necessary to remove the axle hub/steering knuckle assembly to access the lower ball joint

To install:
  1. Install the lower ball joint to the control arm. Thread the nut onto the shaft, then torque to 58 ft. lbs. (78 Nm). Install a new cotter pin.
  2.  
  3. Connect the lower control arm to the steering knuckle. Torque the nuts/bolts to 59 ft. lbs. (80 Nm).
  4.  
  5. Lower the vehicle and check for proper operation.
  6.  

1987-94 Sedans
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the axle hub/steering knuckle assembly. Refer to the procedure in this section.
  4.  
  5. Remove the cotter pin and nut from the ball joint stud.
  6.  
  7. Using SST 09610-55012 (1987-90), 09628-62011 (1991-94) or their equivalent, press the ball joint from the knuckle assembly.
  8.  

To install:
  1. Install the lower ball joint to the steering knuckle, then torque the nut to 72 ft. lbs. (98 Nm). Install a new cotter pin.
  2.  
  3. Install the axle hub/steering knuckle assembly on the vehicle.
  4.  
  5. Lower the vehicle and check for proper operation.
  6.  

 
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