Chevrolet Sonic Repair Manual: Front Wheel Drive Shaft Inner Joint and Boot Replacement
Special Tools
DT-35910 Drive Axle Boot Clamp Pliers
For equivalent regional tools, refer to Special Tools.
- Disassemble Procedure
-
Note:
There are types of inner joints available. If the inner
joint is connected with the CV style joint, the inner joint is not serviced
separately. The inner joint is serviced with the wheel drive shaft as an
assembly. If the inner is a tripot type joint follow the procedure below.
- Remove the wheel drive shaft from the vehicle. Refer to Front Wheel
Drive Shaft Replacement.
- Install the wheel drive shaft in a soft jawed vise.
- Using a pair of side cutters, remove and discard the small boot clamp (4)
from the boot (3).
- Using the appropriate tool, remove and discard the large boot clamp (2) from
the boot (3).
- Remove the boot (3) from the from the tripot housing (1).
- Remove the inner tripot housing (1) from the wheel drive shaft (3).
- Using the appropriate tool, remove the outer tripot spider retaining
ring (1) from the wheel drive shaft (5).
- Remove the tripot spider (2) from the wheel drive shaft (5).
- Using the appropriate tool, remove the inner tripot retaining ring (3),
if equipped, from the wheel drive shaft (5).
- Remove the wheel drive shaft boot (4) from the wheel drive shaft (5).
- Inspect the wheel drive shaft inner joint. Refer to Wheel Drive Shaft
Inner Joint Inspection.
- Assemble Procedure
-
- Install the boot (1) on the wheel drive shaft (3).
- Ensure that the boot (1) is properly seated in the groove (2) in the
wheel drive shaft.
- Using the appropriate tool, install the inner tripot retaining ring (3),
if equipped.
- Install the tripot spider (2) until just touches the shoulder on the
wheel drive shaft (5).
- Using the appropriate tool, install the outer tripot spider retaining
ring (1).
- Using the DT-35910 drive axle boot clamp pliers with a ratchet
wrench and a breaker bar (1), close the boot clamp (2) until the gap (3) measures
1.8 mm (0.07 in)
.
- Install the tripot housing (1) on the wheel drive shaft (3).
- Install the wheel drive shaft boot (3) on the tripot housing (1).
- Place approximately half of the lubricant (2) in the boot (1) and the
remaining half in the tripot housing (3).
Note:
Ensure that the boot clamp is properly positioned around
the entire circumference of the boot.
- Using the DT-35910 drive axle boot clamp pliers (3), a ratchet
wrench (4) and a breaker bar (5), close the boot clamp (1) until the gap (6) measures
1.9 mm (0.07 in)
.
- Remove any of the excess lubricant from the tripot housing and wheel
drive shaft.
- Move the tripot joint housing in a circular motion to distribute the
lubricant in the tripot housing.
- Remove the wheel drive shaft from the vise.
- Install the wheel drive shaft in the vehicle. Refer to Front Wheel Drive
Shaft Replacement.
Front Wheel Drive Intermediate Shaft Replacement
Callout
Component Name
Preliminary Procedure
Raise and support the vehicle. Refer ...
Special Tools
DT-35910 Drive Axle Boot Clamp Pliers
For equivalent regional tools, refer to Special Tools
Disassemble Procedure
Remove the wheel drive shaft from the vehicle. Refer ...
Other materials:
Dimensions - Body (4NB)
Point-to-point measurements are for reference only. All measurements are given
in millimeters. Use these measurements for diagnosing and estimating. Point-to-point
measurements are duplicated with tram bar pointers set at equal lengths. All die
marks, holes, slots, and fasteners are measured t ...
Seat Adjustment
Manual Seats
To adjust a manual seat:
Pull the handle at the front of the seat.
Slide the seat to the desired position and release the handle.
Try to move the seat back and forth to be sure it is locked in place.
See Seat Adjustment.
Seat Height Adjuster
...
Steering Linkage Outer Tie Rod Inspection
Special Tools
GE-8001 Dial Indicator Set
For equivalent regional tools, refer to Special Tools.
Note: This inspection procedure does not supersede local government
required inspections that have more stringent requirements.
Inspect the outer tie rod seal. If the outer tie rod ...
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