Chevrolet Sonic Repair Manual: Front Wheel Drive Shaft Replacement

Special Tools

J-45859 Axle Remover

For regional equivalent tools, refer to Special Tools.

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.



2. Remove the front suspension skid plate bolts (1) and the front suspension skid plate (2).
3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.




Caution:

Make sure that the wheel drive shaft nut is fully un-staked to avoid damage to the wheel drive shaft threads during the removal of the wheel drive shaft nut. Failure to follow these instructions could result in wheel, nut, and/or stud damage.

4. Insert a brass drift or punch (1)  in the cooling fins of the front brake rotor (2).
5. Rotate the brake rotor until it comes in contact with the brake caliper mount bracket (5).
6. Using the proper size socket (3) and a breaker bar (4), loosen the wheel drive shaft nut.


7. Remove and discard the wheel drive shaft nut (1). Replace with NEW only.



Note:

Reverse the wheel lug nuts and washers so the flat part of the wheel nut is facing the washers.

8. Attach the J-45859 remover (1) to the wheel hub using the wheel lug nuts (2).
9. Using the J-45859 remover (1) , separate the wheel drive shaft from the wheel bearing/hub.
10. Remove the stabilizer shaft link from the front strut. Refer to Stabilizer Shaft Link Replacement.
11. Remove the outer tie rod end from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement.
12. Remove the lower control arm bolt from the steering knuckle. Refer to Lower Control Arm Replacement.
13. With the aide of an assistant, move the steering knuckle to the side.


14. Using a long screw driver (2), remove the wheel drive shaft (1) from the transmission.


15. Remove the wheel drive shaft (1) from the vehicle.



Note:

If there is no washer on the wheel drive shaft, install a NEW washer.

16. Remove and discard the washer (1) from the wheel drive shaft (2). Do not re-use the washer, replace with NEW only.

Installation Procedure

1. Position the wheel drive shaft (1) in the vehicle.


2. Install the special tool (1) in the output shaft seal.
3. Install the wheel drive shaft (2).
4. Remove the special tool (1).
5. Install the lower control arm ball joint bolt to the steering knuckle. Refer to Lower Control Arm Replacement.
6. Install the stabilizer shaft link to the front strut. Refer to Stabilizer Shaft Link Replacement.
7. Install the outer tie rod to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement.



8. Install the NEW wheel drive shaft nut (1).


9. Insert a brass drift or punch (5)  in the cooling fins of the front brake rotor (4).
10. Rotate the brake rotor until it comes in contact with the brake caliper mount bracket (1).



Caution:

 Refer to Fastener Caution.

Note:

• There are two types of the wheel drive shaft nuts, which have different tightening torque specifications. Check the style nut that is on the vehicle when staking the nut.
• Style 1 nut has the thin collar (1.5 mm) thickness.
• Style 2 nut has the thick collar (2.7 mm) thickness.
11. Using the proper size socket and torque wrench, tighten the NEW wheel drive shaft nut to:

• For Style 1, 330 Y (244 lb ft)

• For Style 2, First Pass: 50 Y (37 lb ft)

• For Style 2, Final Pass: plus 60 degrees.

Using appropriate tools (3), stake the wheel drive shaft nut collar into the slot on the wheel drive shaft.

• Style 1: Stake the center of the wheel drive shaft nut (1) and ensure it is fully staked. DO NOT fractured the wheel drive shaft nut. Each side of the stake should be in contact with the slot in the wheel drive shaft. The gap between the bottom of the stake in the wheel drive shaft nut and the bottom of the slot in the wheel drive shaft should be less than 1 mm (0.039 in)

  .

• Style 2: Evenly split the center of the wheel drive shaft nut (2) and ensure that it is fully staked. Each side of the stake should be in contact and approximately 45° to each side of the slot in the wheel drive shaft.

Install the front suspension skid plate (2).

Install the front suspension skid plate bolts (1) and tighten to 22 Y (16 lb ft).

Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

Remove the support and lower the vehicle.

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