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:
Charging System Light
This light will come on briefly when the ignition is turned on, and the engine
is not running, as a check to show it is working.
It should go out when the engine is started. If it stays on, or comes on while
driving, there may be a problem with the electrical charging system. Have it checked ...
Seat Adjustment
Manual Seats
Warning: You can lose control of the vehicle if you try to adjust
a driver seat while the vehicle is moving. Adjust the driver seat only when
the vehicle is not moving.
To adjust a manual seat:
Pull the handle at the front of the seat.
Slide the ...
Special Tools
Illustration
Tool Number/ Description
BO-38185
J-38185
Hose Clamp Pliers
BO-42220
J-42220
Universal 12V Leak Detection Lamp
CH-37872
GE-30206952
3-02 ...
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