Toyota Tercel 1984-1994 Repair Guide

MacPherson Struts

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3


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!

Wagons and 1984-86 Sedans
  1. Working from inside the car, remove the trim plate covering the strut attaching nuts.
  2.  
  3. Raise the rear of the vehicle and support it with jackstands (do not place stands under the suspension arms). Remove the wheel.
  4.  
  5. Disconnect the brake line and flexible hose at the mounting bracket on the strut tube. Plug the open lines. Remove flexible hose from the strut.
  6.  
  7. If you will be overhauling the strut assembly, loosen the support nut from inside the car. DO NOT remove it at this time.
  8.  



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Fig. Fig. 1: On wagons and 1984-86 sedans, matchmark the position of the strut assembly to the axle carrier before removing the attaching bolts

  1. Matchmark the position of the strut to the axle carrier, then remove the strut lower attaching bolts/nuts.
  2.  



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Fig. Fig. 2: Removing the bolt(s) securing the strut to the rear axle assembly

  1. From inside the car, remove the nuts holding the strut assembly to the body.
  2.  



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Fig. Fig. 3: Removing the upper attaching nuts

To install:
  1. Position the strut assembly on the vehicle. Install the nuts attaching the strut assembly to the body, then torque the bolts to 17 ft. lbs. (24 Nm).
  2.  
  3. Connect the strut assembly to the axle carrier. Torque the nuts to 105 ft. lbs. (142 Nm).
  4.  
  5. Torque the support nut to 36 ft. lbs. (49 Nm), if applicable.
  6.  
  7. Connect the brake tubes and install the flexible hose to the strut assembly. Bleed the brake system.
  8.  
  9. Lower the vehicle and check for proper operation. Have the alignment checked by a reputable shop.
  10.  

1987-94 Sedans
  1. On some models, it will necessary to remove the rear seat to gain access to the strut upper attaching bolts/nuts.
  2.  
  3. Raise the rear of the vehicle and support the body with jackstands. Remove the wheel(s).
  4.  
  5. Remove the nut/bolt securing the bottom of the strut to the axle beam.
  6.  
  7. Remove the nuts securing the strut to the body from inside the vehicle, then remove the strut assembly.
  8.  

To install:
  1. Connect the strut assembly to the body. Torque the nuts to 23 ft. lbs. (31 Nm).
  2.  
  3. Connect the strut assembly to the axle beam. Tighten the bolt until it is just snug.
  4.  
  5. Install the wheel(s), then lower the vehicle. Bounce the vehicle to stabilize the suspension.
  6.  
  7. Torque the nut attaching the strut to the axle beam to 50 ft. lbs. (68 Nm).
  8.  

OVERHAUL



See Figures 4 through 9


CAUTION
This procedure requires the use of a spring compressor; it cannot be performed without one. IF YOU DO NOT HAVE ACCESS TO THIS SPECIAL TOOL, DO NOT ATTEMPT TO DISASSEMBLE THE STRUT! The coil springs are retained under considerable pressure. They exert enough force to cause serious personal injury and component damage. Exercise extreme caution when disassembling the strut.


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!

  1. Remove the strut from the vehicle. Refer to the appropriate procedure in this section.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: Compress the coil spring before removing the support nut

  1. Compress the coil spring. Use SST 09727-22032 on 1984-90 models and SST 09727-30020 on 1991-94 models.
  2.  
  3. Hold the upper support, then remove the nut on the end of the shock piston rod.
  4.  



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Fig. Fig. 5: Removing the support nut

  1. Remove the support, coil spring, insulator and bumper. Make a note as to their order.
  2.  

Check the shock absorber by moving the piston shaft through its full range of travel. It should move smoothly and evenly throughout its entire travel without any trace of binding or notching. Inspect the spring for any sign of deterioration or cracking. The waterproof coating on the coils should be intact to prevent rusting.

Do not turn the piston rod within the cylinder if the piston rod is fully extended. Never reuse the support nut.



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Fig. Fig. 6: Make sure the spring is correctly positioned in its seat

  1. Assemble all components in order onto the the strut assembly. Make sure the spring end aligns with the hollow in the lower seat.
  2.  



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Fig. Fig. 7: Aligning the lower bracket with the suspension support on wagons and 1984-86 sedans

  1. Align the suspension support with the strut lower bracket. This assures the spring will be properly seated top and bottom.
  2.  



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Fig. Fig. 8: Aligning the lower bracket with the suspension support on 1987-90 sedans



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Fig. Fig. 9: Aligning the lower bracket with the suspension support on 1991-94 sedans

  1. Thread a new support nut onto the piston rod, then tighten it to 40 ft. lbs. (54 Nm) on 1987-94 Sedans. Do not torque the support nut on wagons and 1984-86 sedans at this time.
  2.  
  3. Install the strut on the vehicle.
  4.  

 
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