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:
When It Is Time for New Tires
Factors such as maintenance, temperatures, driving speeds, vehicle loading, and
road conditions affect the wear rate of the tires.
Treadwear indicators are one way to tell when it is time for new tires. Treadwear
indicators appear when the tires have only 1.6mm (1/16 in) or less of tread rema ...
Draining Fluids and Oil Filter Removal
Place a drip pan underneath.
Remove the oil filter cap (1).
Remove the oil filter cap seal (2).
Remove and properly dispose of the oil filter insert (3).
Re-install the oil filter cap.
Remove the oil drain bolt.
Drain the engine oil into the drip pan.
...
Clutch Master Cylinder Reservoir Hose Replacement
Removal Procedure
Note: Before disconnecting the reservoir tank hose, remove
the clutch/brake fluid from the reservoir tank.
Remove the clutch master cylinder reservoir hose (1)
from the reservoir tank.
Remove the clutch master cylinder reservoir ...
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