MR2 L4-1587cc 1.6L DOHC (4A-GE) (1986)
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d. Check boots for damage.
2.
Remove deflector (if equipped), Fig. 7.
3.
Remove boot clamps.
4.
Place alignment marks on inboard joint tulip and tripod. Do not punch alignment marks.
5.
Remove inboard joint tulip from axle shaft.
6.
Disassemble tripod joint as follows:
a. Using suitable pliers, remove snap ring.
b. Using punch, place alignment marks on shaft and tripod.
c. Using hammer and brass bar, drive out tripod joint from axle shaft.
7.
Remove inboard joint boot, right side axle shaft damper (if equipped) and the outboard joint boot.
8.
Provisionally install boot and new boot clamp to outboard joint as follows. Before installing boot, wrap vinyl tape around spline of shaft to
prevent damaging boot.
a. Provisionally install new boot and clamp to outboard joint.
b. Install right side axle shaft damper (if equipped) and new clamp.
c. Provisionally install new boot and clamp to the outboard joint.
9.
Assemble tripod joint as follows:
a. Face beveled side of tripod axial spline toward outboard joint.
b. Align marks made during disassembly.
c. Using brass bar and hammer, tap tripod onto axle shaft.
10.
Install new snap ring.
11.
Using grease supplied in boot kit, pack .26 lb. into tulip and boot, then assemble boot to outboard joint.
12.
Assemble inboard joint tulip to axle shaft as follows:
a. Using grease supplied in boot kit, pack .47 lb. on models with man. trans. or .36 lb. on models with auto. trans. into tulip and boot.
b. Align marks made during disassembly.
c. Install inboard joint tulip to axle shaft.
d. Install boot to inboard joint tulip.
13.
Assemble boot clamps to both boots as follows:
a. Ensure boot is on shaft groove.
b. Bend and lock band.
Fig. 8 Measuring driveshaft length. 1985-87 MR2 (1988 MR2 with 4A-GZE engine similar)
c. On 1985-86 models, ensure that boot is not stretched or contracted when axle shaft is at standard length, Fig. 8. Standard length is when ``A''
equals 26.97 inches (685 mm), ``B'' equals 7.95 inches (202 mm) and ``C ''equals 17.28 inches (439 mm).
d. On 1987-88 models, ensure boot is not stretched or contracted when driveshaft is at standard length ``C'', Fig. 8. Standard length is as
follows: left side, man. trans., 17.09-17.49 inches; left side, auto. trans., 16.98-17.37 inches; right side, man. trans., 26.77-27.16 inches; right
side, auto. trans., 26.84-27.24 inches.
14.
Install deflector, if equipped.
On models equipped with 4A-GZE engine, proceed as follows:
1.
Check driveshaft. Ensure there is play in the inboard and outboard joint. Ensure that the inboard joint slides smoothly in the thrust direction.
Ensure there is no play in the radial direction of the inboard joint. Check for boot damage.
