Chevrolet Sonic Repair Manual: Front Wheel Drive Shaft Outer Joint and Boot Replacement
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 to Front Wheel
Drive Shaft Replacement.
- Install the drive axle shaft (1) in a soft jawed vice.
Caution:
Do not cut through the wheel drive shaft inboard
or outboard boot during service. Cutting through the boot may damage
the sealing surface of the housing and the tripot or the constant velocity
joint bushing. Damage to the sealing surface may lead to water and dirt
intrusion and premature wear of the constant velocity joint.
- Using a pair of side cutters, remove the outer boot clamp (1) and the
inner boot clamp (2).
- Discard the boot clamps (1) and (2). Use NEW clamps only.
- Remove the CV joint (2) from the wheel drive shaft (1) while tapping
the inner race (3) using a bronze bar and a hammer.
- Using the appropriate tool, remove and discard the retaining clip.
- Remove the boot (1) from the wheel drive shaft (2).
- Inspect the outer CV joint for damage and wear. Refer to Wheel Drive
Shaft Outer Joint Inspection.
- Assemble Procedure
-
- Position the boot (1) on the wheel drive shaft (2).
- Using the appropriate tool, install the NEW retaining clip.
- Ensure that the boot (1) is properly seated in the grooved (2) wheel
drive shaft (3).
- Place approximately half the lubricant from the service kit inside the
outboard boot and pack the CV joint with the remaining lubricant.
- Using a block of wood and a hammer, install the CV joint (1) on the
wheel drive shaft.
- Install the inner boot clamp (2) and the outer boot clamp (1).
Note:
Ensure that the boot clamp is properly positioned around
the entire circumference of the boot.
- Using the DT-35910 pliers and a torque or ratchet wrench and
breaker bar (1), close the boot clamp (2) until the gap (3) measures
1.9 mm (0.07 in)
.
- Using the DT-35910 pliers and a torque or ratchet wrench (2) and
breaker bar (3), close the boot clamp (1) until the gap (4) measures
1.7 mm (0.06 in)
.
- Distribute the lubricant within the outer CV joint by moving it in a
circular motion at least four to five times.
- Remove the wheel drive shaft from the bench vise.
- Install the wheel drive shaft assembly. Refer to Front Wheel Drive Shaft
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 ...
Special Tools
J-45859 Axle Remover
For regional equivalent tools, refer to Special Tools.
Removal Procedure
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
...
Other materials:
Special Tools
Illustration
Tool Number/ Description
EN-45059
J-45059
Angle Meter
...
Intake Manifold Assemble (1.8L LUW and LWE)
Install the 4 NEW multiport fuel injector seals (4).
Install the multiport fuel injection fuel rail (2) and the fuel injectors (3)
to the intake manifold (5).
Caution: Refer to Fastener Caution.
Install the 2 multiport fuel in ...
Front Wheel Drive Shaft Seal Replacement - Torque Converter Housing Side
Front Wheel Drive Shaft Seal Replacement - Torque Converter Housing
Side
Callout
Component Name
1
Front Wheel Drive Shaft Oil Seal Assembly
Special Tools
DT-23129 Universal Seal Remover
DT-47790 Seal Insta ...
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